MAN Service ManualD2842

Technical information
MAN industrial Diesel engines
Service record book

Dear Customer,
Congratulations on your decision to purchase a MAN Diesel engine. These engines boast top performance
and operational reliability while requiring only a minimum of maintenance. However, to ensure faultless
operation, some checks and maintenance work are necessary at regular intervals.
This handbook provides an overview of all specified maintenance work.
Service work has to be carried out on the basis of operating hours clocked up according the checklists (pa-
ges 11 and following) by MAN-authorised workshops.
To make it easier for you to handle your new engine correctly, the following publications are available:
D Operating Instructions
D Fuels, Lubricants, Coolants for Industrial and Marine Diesel Engines
D Spare-parts catalogue
D Service record
We shall be pleased to answer your questions on aspects which cannot be clarified with these publications.
When submitting an enquiry, please always indicate the 14-digit engine number which you can find on
the form “General data” on page 3 or on the model plate on the engine.
Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg Works
We reserve the right to make technical modifications in the course of further development.
 1999 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying or translation, even in the form of excerpts, is forbidden without the written permission
of MAN. MAN expressly reserves all rights in accordance with the law on copyright.
MTDA / 05.99 51.99597-8007
1
Notes
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2
General data
Name and address of owner
Data on engine
Engine model: Output in kW:
Works number: Date of commission:
Engine number: Engine speed in rpm:
Name of MAN agent:
Data on drive system

Type of drive system (e.g. generator, pump):
Construction number, year of construction:
Place and date of 20-60 hour service:
3
Notes
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4
Maintenance procedure
General notes
Please note that servicing must only be carried out by an authorised MAN workshop.
After each service the workshop will confirm that the work has been correctly carried out to checklist by
stamping and signing the service booklet.
Care should be taken that all entries are complete, correct and legible.
A trial run is to be made after each service.
Notes about work and/or repairs that seem to be necessary or have been carried out can also be recorded.
Servicing for engines in continuous operation (> 3000 h / a) and in peak load oper-
ation (< 3000 h / a)
These engines are regularly serviced every 200 operating hours. Apart from this the screw cap on the cool-
ing system and the coolant are to be changed every 2 and 4 years respectively.
All servicing which must be carried out up to 10 000 operating hours and the regular servicing after 2 or 4
years are listed from page 9.
Servicing for engines for standby operation

These engines generally run for only a few operating hours annually. Servicing is therefore to be carried our
each year.
All servicing that must be regularly carried out up to 10 years is listed from page 115 onwards.
The service after 20-60 operating hours

This first service is imperative.
In the context of the first maintenance the form “General data” on page 3 is to be filled in by the
MAN-authorised workshop.
5
General notes for the workshop on care and maintenance
General:
D Exchange worn seals.
D Tighten screwed connections for which tightening torques are specified (see publication “Engineering S
Data S Setting values”), always using a torque wrench.
D Clean removed parts before refitting them, and check them for damage unless exchange is mandatory.
When checking the engine oil level or changing the engine oil
D The procedure for changing engine oil and oil filters is described in the Operating Instructions in the
chapter “Maintenance and care”.
D Keep vicinity of filler orifices and of dipsticks clean, so that no dirt can get into the oil pan.
D Caution: Do not fill up with oil beyond the max. notch on the dipstick. Overfilling causes damage to
engine.
D If loss of oil is due to leaks, ascertain and eliminate cause.
When checking the coolant level

D Top up with missing quantity of fluid, ensuring that the concentration of the antifreeze / anti-corrosion
agent is correct (see Operating Instructions, chapter “Maintenance and care” and the publication “Fuels,
Lubricants, Coolants for MAN Diesel Engines”).
D Ascertain and eliminate cause of loss of coolant.
When changing the coolant

D Drain and fill up with coolant and bleed cooling system as described in the Operating Instructions,
chapter ”Maintenance and care”.
D For antifreeze / anti-corrosion agents see publication “Fuels, Lubricants, Coolants for MAN Diesel Engi-
nes”.
When checking for leaks of oil, coolant and fuel

D Carry out visual check of engine exterior (crankshaft, cylinder heads etc.) for emergence of oil.
D Carry out visual check of all fluid-containing parts (reservoirs, pipes, hoses) for leaks.
D Carry out visual check of pipes and hoses to see whether they are correctly routed or show chafing
marks.
Observe safety instructions in the Operating Instructions!
6
The warranty conditions
Extent of warranty
MAN warrants that within the period of the warranty all D 08 and D 28 engines components identified as
being faulty will, at MAN’s discretion, be either replaced or repaired, the warranty conditions being decisive
for this.
Repairs
For execution of the necessary work the customer has to
D grant the necessary time and opportunity,
D provide at his own expense helpers, machinery and equipment and carry out secondary work,
D perform at his own expense any work above and beyond the original extent of the order.
Depending on the kind of damage, MAN will assume to a reasonable amount both the travelling expenses
arising for authorised service technicians and the necessary dispatch costs for spare and replacement
parts. Extra costs in connection with particular travelling and dispatch expenses are to be borne by the cus-
tomer. Repairs will be performed within normal, regular working hours. Extra costs for work outside regular
working hours are to be borne by the customer.
The warranty does not include

D the exchange of wearing parts such as filters, V-belts and service products (oil, antifreeze and anti-cor-
rosion agents),
D the costs of the execution of the normal service work to be carried out at regular intervals,
D damage resulting from the use of unsuitable service products or from improper handling / operation,
D indirect costs of loss of use, of loss of time, of expenses for board and lodging, of freight charges, of fuel
and of all other consequential costs which may be incurred in connection with warranty cases,
D any damage which arises if the ”Installation instructions for industrial diesel engines” are disregarded.
7
Notes
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8
Engines for continuous operation
9
Notes
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10
Service according to chronological intervals
In addition to the service on the basis of operating hours clocked up the following
maintenance work according to chronological intervals are necessary:
Checklist for maintenance work
Changed (= x) after years

Changing of 2 4 6 8 10
Both valve caps on expansion tank
ÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍ
Coolant
ÍÍÍÍ ÍÍÍÍÍ ÍÍÍÍ
Service work carried out after 2 years:
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Place: Date Stamp / signature
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11
Notes
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12
Service after 20-60 operating hours
Checklist for the maintenance work 20-60

Checking of Checked = x / Data
Engine exterior for loss of oil and coolant
Coolant level
Concentration of antifreeze / anti-corrosion agents
Engine oil level
Engine alarms, emergency stop device, overspeed protection
Functioning of instruments
Coolant preheating, function, setting
Coolant hoses for leaks
Fuel lines for leaks
V-belt tension, retightening if necessary V-belt(s)
Draining water from auxiliary fuel filter
Water hose clamps, pipe connections and bolts for security,
retightening if necessary
Cleaning of
Fuel pre-filter
Test run
done
Once the respective number of operating hours has been clocked up, the aforementioned maintenance
work is to be carried out by an MAN-authorised workshop.
Service done by
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Place Data Stamp / Signature
13
Service after 20-60 operating hours
Remarks: ............................................................................................................................
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14
Service after 200 operating hours
Checklist for the maintenance work 200

Coolant level
Engine oil level
Changing of
Engine oil *
Engine oil cartridge(s) *
Servicing the air cleaner (earlier if severe operating conditions demand it)
Cleaning of
Fuel pre-filter
Test run
done
* not when using high-performance engine oil
work is to be carried out by an MAN-authorised workshop. In addition please note the seperately listed
maintenance work in chronological intervals, see page 11.
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Retightening of cylinder head bolts (D 28 engines only)
Valve clearance, setting if necessary
Changing of
Engine oil
Engine oil cartridge(s)
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done

Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done

Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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Remarks: ............................................................................................................................
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48

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
49
Remarks: ............................................................................................................................
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50

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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51
Remarks: ............................................................................................................................
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52

Coolant level
Engine oil level
V-belt idler pulley, replacing if necessary
Clearance of engine water pump bearing
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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53
Remarks: ............................................................................................................................
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54

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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55
Remarks: ............................................................................................................................
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56

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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57
Remarks: ............................................................................................................................
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58

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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59
Remarks: ............................................................................................................................
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60

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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61
Remarks: ............................................................................................................................
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62

Coolant level
Engine oil level
Changing of
Engine oil *
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done

Service done by
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63
Remarks: ............................................................................................................................
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64

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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65
Remarks: ............................................................................................................................
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66

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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67
Remarks: ............................................................................................................................
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68

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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69
Remarks: ............................................................................................................................
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70

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
71
Remarks: ............................................................................................................................
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72

Coolant level
Engine oil level
Injectors, replacing if necessary (see following page)
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
73
Opening pressure of injection nozzles
Cylin- Opening Remarks

der pressure (tightness, jet pattern)
1 bar
2 bar
3 bar
4 bar
5 bar
6 bar
7 bar
8 bar
9 bar
10 bar
11 bar
12 bar
Remarks: ............................................................................................................................
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74

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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75
Remarks: ............................................................................................................................
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76

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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77
Remarks: ............................................................................................................................
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78

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
79
Remarks: ............................................................................................................................
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80

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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81
Remarks: ............................................................................................................................
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82

Coolant level
Engine oil level
Changing of
Engine oil *
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done

Service done by
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83
Remarks: ............................................................................................................................
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84

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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85
Remarks: ............................................................................................................................
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86

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
87
Remarks: ............................................................................................................................
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88

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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89
Remarks: ............................................................................................................................
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90

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
91
Remarks: ............................................................................................................................
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92

Coolant level
Engine oil level
V-belt idler pulley, replacing if necessary
Clearance of engine water pump bearing
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
Ort Datum Stempel / Unterschrift
93
Remarks: ............................................................................................................................
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94

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
95
Remarks: ............................................................................................................................
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96

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
97
Remarks: ............................................................................................................................
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98

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
99
Remarks: ............................................................................................................................
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100

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
101
Remarks: ............................................................................................................................
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102

Coolant level
Engine oil level
Changing of
Engine oil *
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done

Service done by
...............................................................................
103
Remarks: ............................................................................................................................
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104

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
...............................................................................
105
Remarks: ............................................................................................................................
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106

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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107
Remarks: ............................................................................................................................
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108

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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109
Remarks: ............................................................................................................................
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110

Coolant level
Engine oil level
Changing of
Engine oil *
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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111
Remarks: ............................................................................................................................
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112
Service after 10 000 operating hours
Checklist for the maintenance work 10 000

Coolant level
Engine oil level
Compression (see following page)
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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113
Service after 10 000 operating hours
Compression pressures of cylinders
Cylin- Compression Remarks

der pressure
1 bar
2 bar
3 bar
4 bar
5 bar
6 bar
7 bar
8 bar
9 bar
10 bar
11 bar
12 bar
Remarks: ............................................................................................................................
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114
Engines for standby operation
115
Notes
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116
Service for standby engines 1 year after commissioning
Checklist for the maintenance work 1 year

Coolant level
Engine oil level
Retightening of cylinder head bolts (D 28 engines only)
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Once the respective operating time has been clocked up, the aforementioned maintenance work is to be
carried out by an MAN-authorised workshop.
Service done by
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117
Service after 1 year
Remarks: ............................................................................................................................
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118
Service for standby engines 2 years after commissioning
Checklist for the maintenance work 2 years

Coolant level
Engine oil level
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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119
Service after 2 years
Remarks: ............................................................................................................................
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120

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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121
Remarks: ............................................................................................................................
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122

Coolant level
Engine oil level
Changing of
Engine oil
Fuel filter
Coolant
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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123

1 bar
2 bar
3 bar
4 bar
5 bar
6 bar
7 bar
8 bar
9 bar
10 bar
11 bar
12 bar
Remarks: ............................................................................................................................
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124
Checkliste für die Wartungsarbeiten 5 years

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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125
Remarks: ............................................................................................................................
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126

Coolant level
Engine oil level
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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127
Remarks: ............................................................................................................................
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128

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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129
Remarks: ............................................................................................................................
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130

Coolant level
Engine oil level
Changing of
Engine oil
Fuel filter
Coolant
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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131

1 bar
2 bar
3 bar
4 bar
5 bar
6 bar
7 bar
8 bar
9 bar
10 bar
11 bar
12 bar
Remarks: ............................................................................................................................
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132

Coolant level
Engine oil level
Changing of
Engine oil
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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133
Remarks: ............................................................................................................................
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134

Coolant level
Engine oil level
Changing of
Engine oil
Fuel filter
Cleaning of
Fuel pre-filter
Test run
done
Service done by
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135
Remarks: ............................................................................................................................
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136
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33 Telefon (0911) 420-0
D-90441 Nürnberg Telefax (0911) 420-1967
Telex 6 22 291 mn d
GB Printed in Germany TDA-N 51.99597-8007

MAN Service ManualD2842

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MAN Service ManualD2842

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Technical information

MAN industrial Diesel engines

Service record book

 1999 MAN Nutzfahrzeuge Aktiengesellschaft

MTDA / 05.99 51.99597-8007

Name and address of owner

Works number: Date of commission:

Engine number: Engine speed in rpm:

Name of MAN agent:

Data on drive system

Construction number, year of construction:

Place and date of 20-60 hour service:

Servicing for engines for standby operation

The service after 20-60 operating hours

When checking the coolant level

When changing the coolant

When checking for leaks of oil, coolant and fuel

Observe safety instructions in the Operating Instructions!

The warranty does not include

Checklist for maintenance work

Changed (= x) after years

Service work carried out after 4 years:

Service work carried out after 6 years:

Service work carried out after 8 years:

Service work carried out after 10 years:

Checklist for the maintenance work 20-60

Checklist for the maintenance work 200

Checklist for the maintenance work 400

Checklist for the maintenance work 600

Checklist for the maintenance work 800

Checklist for the maintenance work 1000

* not when using high-performance engine oil

Checklist for the maintenance work 1200

Checklist for the maintenance work 1400

Checklist for the maintenance work 1600

Checklist for the maintenance work 1800

Checklist for the maintenance work 2000

Checklist for the maintenance work 2200

Checklist for the maintenance work 2400

Checklist for the maintenance work 2600

Checklist for the maintenance work 2800

Checklist for the maintenance work 3000

* not when using high-performance engine oil

Checklist for the maintenance work 3200

Checklist for the maintenance work 3400

Checklist for the maintenance work 3600

Checklist for the maintenance work 3800

Checklist for the maintenance work 4000

Checklist for the maintenance work 4200

Checklist for the maintenance work 4400

Checklist for the maintenance work 4600

Checklist for the maintenance work 4800

Checklist for the maintenance work 5000

* not when using high-performance engine oil

Checklist for the maintenance work 5200

Checklist for the maintenance work 5400

Checklist for the maintenance work 5600

Checklist for the maintenance work 5800

Checklist for the maintenance work 6000

Opening pressure of injection nozzles

Cylin- Opening Remarks

Checklist for the maintenance work 6200

Checklist for the maintenance work 6400

Checklist for the maintenance work 6600