Man D 0826 LE User manual

Operating Instructions
Diesel Engine
D 0826 LE
D 0826 LE 201

Preface
1
Dear Customer
These Operating Instructions are intended to familiarize you with your new MAN Diesel
engine and how it operates.
This manual is supplemented by the publication “Fuels, Lubricants and Coolants for MAN
Diesel Engines” and the “Service record”.
Note:
All three publications belong to the engine and must always be kept ready to hand
near the engine in the engine room.
Please read this Manual and the “Instructions for the installation of MAN Diesel Engines”
before you put the new engine into operation.
Comply in full with instructions relating to operation, prevention of accidents and envi-
ronmental protection.
MAN Diesel engines are developed and manufactured in line with the latest state of the
art. However, trouble-free operation and high performance can only be achieved if the
specified maintenance intervals are observed and only approved fuels, lubricants and
coolants are used.
It is imperative and in your own interest to entrust your MAN Local Service Centre with
the removal of any disturbances and with the performance of checking, setting, and re-
pair work.
Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Werk Nürnberg
Subject to change to keep abreast with technological progress.
2002 MAN Nutzfahrzeuge Aktiengesellschaft
No parts of this publication may be reproduced or translated without prior written per-
mission of MAN. MAN explicitly reservs all rights according to copyright law.
MTDA Technical status: 03.2002 51.99493–8251

Index
2
Declaration 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplates 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety regulations 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical information
Engine views 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine lubrication 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intercooler 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air cleaner 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical equipment 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning and operation
Preparations 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Running in 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
During operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting down 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary decommissioning of engines 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and care
Engine lubrication 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air cleaner 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and setting
To check and set the start of delivery 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To check and adjust valve clearance 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head bolts 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For data see original declaration
If required this declaration is
enclosed with the delivery note.
Declaration
3
Declaration
In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of
Directive 89/392/EEC, version 93/44/EEC
MAN Nutzfahrzeuge Aktiengesellschaft,
hereby declares that the engine described below is destined for installation in a machine
as defined in the EC directive on machines.
Engine model:
Design:
Engine number:
Rating / speed:
Note:
The manufacturer of the complete ready-to-use machine in which this engine is to be
installed must take the further action necessary in the context of indirect safety-re-
lated engineering and provision of instructions to ensure that the ready-to-use
machine complies with the requirements of the EC directive on machines.
The engine must not be put into operation until the complete machine satisfies the
conditions laid down in the EC directive on machines 89/392/EEC, most recently
amended by 93/44/EEC, or the latest amendment of said directive.
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33
D–90441 Nürnberg

Nameplates
4
Model
......................................................................
delivered on
......................................................................
installed on
......................................................................
Enter 14-digit serial number (is used in the
spare parts catalog to distinguish between
spare parts).
In all your correspondence please always
quote engine model, serial number and job
number (Order number).
Enter 14-digit engine serial
number.
Enter 6-digit job number (Or-
der number).
MAN Nutzfahrzeuge Aktiengesellschaft
Typ
Motor-Nr. / Engine No. NI/II
Temp. C
Werk Nürnberg Germany
:
MAN Nutzfahrzeuge AktiengesellscMAN Nutzfahrzeuge Aktiengesellschaft
:
:
Altitude mRating BHP
Job No Rating kW Speed rpm
Serial NoModelYear
–0219
Aufstellhohe m uNNLeistg. PS
Drehz. 1/min
Leistung kWWerk–Nr.
Motor–Nr.TypBauj.
°

Safety regulations
5
General notes
Day-to-day use of power engines and the service products (fuels, lubricants, cool-
ants) necessary for running them presents no problems if the persons occupied
with their operation, maintenance and care are given suitable training and think as
they work.
This summary is a compilation of the most important regulations. These are broken down
into main sections which contain the information necessary for preventing injury to per-
sons, damage to property and pollution. In addition to these regulations those dictated by
the type of engine and its site are to be observed also.
Important:
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the
eyes etc., consult a doctor immediately.
1. Regulations designed to prevent accidents with injury to persons
During commissioning, starting and operation
DBefore putting the engine into operation for the first time, read the oper-
ating instructions carefully and familiarize yourself with the “critical”
points. If you are unsure, ask your MAN representative.
DFor reasons of safety we recommend you attach a notice to the door of
the engine room prohibiting the access of unauthorized persons and that
you draw the attention of the operating personal to the fact that they are
responsible for the safety of persons who enter the engine room.
DThe engine must be started and operated only by authorized personnel.
Ensure that the engine cannot be started by unauthorized persons.
DWhen the engine is running, do not get too close to the rotating parts.
Wear close-fitting clothing.
DDo not touch the engine with bare hands when it is warm from operation
– risk of burns.
ËË
DExhaust gases are toxic. Comply with the instructions for the installation
of MAN Diesel engines which are to be operated in enclosed spaces.
Ensure that there is adequate ventilation and air extraction.

Safety regulations
6
DKeep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
During maintenance and care
DAlways carry out maintenance work when the engine is switched off.
If the engine has to be maintained while it is running, e.g. changing the
elements of change-over filters, remember that there is a risk of scald-
ing. Do not get too close to rotating parts.
DChange the oil when the engines is warm from operation.
Caution:
There is a risk of burns and scalding. Do not touch oil drain plugs or oil
filters with bare hands.
ËË
ËË
DTake into account the amount of oil in the sump. Use a vessel of suffi-
cient size to ensure that the oil will not overflow.
DOpen the coolant circuit only when the engine has cooled down.
If opening while the engine is still warm is unavoidable, comply with the
instructions in the chapter entitled “Maintenance and Care”.
DNeither tighten up nor open pipes and hoses (lube oil circuit, coolant cir-
cuit and any additional hydraulic oil circuit) during the operation.
The fluids which flow out can cause injury.
DFuel is inflammable. Do not smoke or use naked lights in its vicinity. The
tank must be filled only when the engine is switched off.
DWhen using compressed air, e.g. for cleaning the radiator, wear goggles.
DKeep service products (anti-freeze) only in containers which can not be
confused with drinks containers.
DComply with the manufacturer’s instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.

Safety regulations
7
2. Regulations designed to prevent damage to engine and premature wear
Do not demand more from the engine than it is able to supply in its intended application.
Detailed information on this can be found in the sales literature. The injection pump must
not be adjusted without prior written permission of MAN Nürnberg.
If faults occur, find the cause immediately and have it eliminated in order to prevent more
serious damage.
Use only genuine MAN spare parts. MAN will accept no responsibility for damage result-
ing from the installation of other parts which are supposedly “just as good”.
In addition to the above, note the following points:
DNever let the engine run when dry, i.e. without lube oil or coolant.
DWhen starting do not use any additional starting aids (e.g. injection with starting pilot).
DUse only MAN-approved service products (fuel, engine oil, anti-freeze and anti-cor-
rosion agent). Pay attention to cleanliness. The Diesel fuel must be free of water. See
“Maintenance and care”.
DHave the engine maintained at the specified intervals.
DDo not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
DNever put cold coolant into an overheated engine. See “Maintenance and care”.
DDo not add so much engine oil that the oil level rises above the max. marking on
the dipstick. Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered to.
DAlways ensure that the testing and monitoring equipment (for battery charge, oil pres-
sure, coolant temperature) function satisfactorily.
DComply with instructions for operation of the alternator. See “Maintenance and care”.

Safety regulations
8
3. Regulations designed to prevent pollution
Engine oil and filter elements / cartridges, fuel / fuel filter
DTake old oil only to an old oil collection point.
DTake strict precautions to ensure that no oil or Diesel fuel gets into the drains or the
ground.
The drinking water supply could be contaminated.
DFilter elements are classed as dangerous waste and must be treated as such.
Coolant
DTreat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.
DWhen disposing of spent coolant comply with the regulations of the relevant local auth-
orities.

Safety regulations
9
4. Notes on safety in handling used engine oil ∗
Prolonged or repeated contact between the skin and any kind of engine oil decreases the
skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal experi-
ments. If the basic rules of hygiene and health and safety at work are observed, health
risks are not to the expected as a result of handling used engine oil.
Health precautions:
DAvoid prolonged or repeated skin contact with used engine oil.
DProtect your skin by means of suitable agents (creams etc.) or wear protective gloves.
DClean skin which has been in contact with engine oil.
– Wash thoroughly with soap and water. A nailbrush is an effective aid.
– Certain products make it easier to clean your hands.
– Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
DAfter washing apply a fatty skin cream to the skin.
DChange oil-soaked clothing and shoes.
DDo not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly
– Engine oil can endanger the water supply –
For this reason do not let engine oil get into the ground, waterways, the drains or the
sewers. Violations are punishable.
Collect and dispose of used engine oil carefully. For information on collection points
please contact the seller, the supplier or the local authorities.
∗Adapted from “Notes on handling used engine oil”.

Technical information
10
Engine views D 0826 LE
1
234
56
7
8910

Technical information
11
1 Fuel filter
2 Starter motor
3 Injection pump
4 Oil filter
5 Oil filler neck
6 Thermostat housing
7 Alternator
8 Oil drain plug
9 Oil dipstick
10 Turbocharger

Technical information
12
Engines
The engine D 0826 LE is in-line vertical liquid-cooled 6-cylinder four-stroke Diesel engine
with direct injection, turbocharger and intercooler.
Engine block
The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is ex-
tended to a level below the crankshaft centre line. The engine has replaceable dry cylin-
der liners and cylinder heads with shrunk-in valve seat rings and replaceable valve
guides. For every two cylinders there is one cylinder head of high-alloy cast iron.
Piston / Conrod / Crank assembly
The integral die-forged crankshaft is carried in seven bearings. Balance of masses is by
integral balance weights.
Sealing of the crankshaft penetration is by radial seals in the flywheel housing and the
timing gear cover.
The connecting rods are horizontally split and can be removed upwards together with the
piston.
Connecting rods and crankshaft run in ready-to-fit thin-walled steel-backed plain bear-
ings with lead bronze lining and a ternary running layer.
The combustion chamber is integrally cast in the crown of the aluminium alloy piston

Technical information
13
Engine timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the water
pump end via an idler gear from the crankshaft.
13
24
5
1 Crankshaft gear (match-marked with idler gear by “D- D- 1”)
2 Idler gear
3 Camshaft gear (match-marked with idler gear by “2 - 2 - 2”)
4 Injection pump drive gear
5 Oil pump drive gear
Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker
arms from the camshaft.

Technical information
14
Engine lubrication
The engine is equipped with force-feed lubrication.
The gear oil pump for the force-feed lubrication system of the engine is fitted on the tim-
ing gear case in a recess of the crankcase and driven by gears.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil
filter to the main distributor gallery and from there to the main bearings, big-end bearings
and camshaft bearings as well as to the small-end bearings and the rocker arms.
10 9 8
7
6
4
5
32
1
11
1 Oil pump 7 Turbocharger
2 Oil relief valve 8 Main oil channel
3 Oil cooler 9 Oil jet for piston cooling
4 Oil filter 10 Timing gear idler
5 Bypass valve 11 Injection pump
6 Switch for oil pressure warning lamp

Technical information
15
The turbocharger and the injection pump are also connected to the engine lubricating
system.
The cylinder walls and timing gears are splash-lubricated.
Each cylinder has an oil jet provided for cooling the underside of the pistons.
The lube oil is cleaned in a full-flow oil filter with internal bypass valve.
Depending on the agreed extent of delivery and the design of the engine, the lube oil cir-
cuit can be equipped with oil pressure monitors (advance warning and cut-off function)
which shut the engine down in the event of a sudden loss of pressure.
Oil cooler
An oil cooler is provided between the oil filter and the crankcase. This cooler is of the flat
tube type with turbulence inserts and operated by the coolant.

Technical information
16
Fuel system
The fuel is delivered by a primary fuel supply pump via the fuel filter to the distributor in-
jection pump.
The fuel is sprayed into the cylinder through four-hole nozzles fitted in screw-fit injectors
in the cylinder heads.
Excessive fuel delivered and leak fuel from the injectors flows through the return pipe to
the tank.
1
6
5
4
2
3
1 Fuel tank 4 Injection pump
2 Fuel supply pump 5 Overflow restrictor
3 Fuel filter 6 Injector
Injection pump
The in-line injection pump is driven from the crankshaft via gears. It is connected to the
force-feed lubricating system of the engine and consequently maintenance-free. The
centrifugal governor attached to the pump by a flange is mechanical variable speed gov-
ernor or a low-idle / maximum speed governor.
Fuel filters
Before entering the suction chamber of the injection pump, the fuel is cleaned in a paral-
lel box filter.

Technical information
17
Turbocharger
The exhaust gases of the engine are passed through the turbine rotor of the turbochar-
ger. Air impeller mounted on the same shaft draws in fresh air and delivers it at a higher
pressure to the cylinders.
The turbocharger is air-cooled. Lubrication of the main bearing is by oil under pressure
from the engine lubricating system.
Air-cooled turbocharger K27
3
1
2
4
AB
C
D
E
1 Compressor casing A Air inlet
2 Turbine casing B Gas outlet
3 Compressor wheel C Gas inlet
4 Turbine rotor D Oil inlet
E Oil return

Technical information
18
Intercooler
Before entering the cylinders the combustion air compressed in the turbocharger is
passed through a heat exchanger (intercooler).
Heat removal in the cooler is either by air (air-to-air intercooler) or, in case of the marine
application, by means of seawater (air-to-water intercooler) delivered by the raw water
pump.
It is important to provide a seawater filter ahead of the air-to-water intercooler.
In the case of extended standstills, cleaned seawater may be left in the intercooler, but
dirty water (brackish water) must definitely be discharged.
The seawater-operated intercooler must be regularly cleaned as required in order to
maintain its full cooling efficiency. If the engine output is found to drop, the reason may
be in a fouled-up intercooler. The intercooler has to be removed from the engine for
cleaning.
Cooling
The engine has a liquid-cooling system.
The water pump is a maintenance-free impeller pump driven by V-belts from the crank-
shaft pulley.
Depending on the agreed extent of delivery and the design of the engine, the coolant cir-
cuit can be equipped with temperature and level monitors which, in the event of over-
heating, will trigger an advance warning system or, in the event of loss of coolant, shut
the engine down.
Air cleaner
Air cleaner is mounted on the engine to purify the air for combustion.
The intervals at which the air cleaner requires servicing depend on the specific operating
conditions encountered. Clogged air filters may cause black smoke and reduce power.
A check should be made from time to time to see that the fastening elements securing
the air cleaner to the intake manifold seal the connection tightly. Any ingress of unfiltered
air is liable to cause a high rate of cylinder and piston wear.