Man D 2840 LE 301 Operating instructions

Preface
1
This Repair Manual is designed to facilitate repair of the engines listed in line with accepted technical
principles.
In addition to this Repair Manual the following publications are available:
DOperating Instructions
DFuels, Lubricants and Coolants for MAN Diesel Engines
DSpare-parts catalogue
DService record book with maintenance plan
Note:
Only use fuels, lubricants etc. in accordance with MAN’s regulations.
Otherwise the manufacturer’s liability for defects will not apply!
For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN
Diesel Engines”.
You can find the approved products on the Internet at:
−http://www.man-mn.com/ "Products & Solutions "E-Business−
The pictures and associated descriptions show typical work that may not always be applicable to the
engine in hand, which nevertheless does not mean that they are not correct.
In such cases, the repair work is to be planned and carried out in a similar way.
It is compulsory that the engine be removed before performing any of the work describe in this Repair
Manual.
The expert knowledge necessary for handling Diesel engines was taken for granted when this publication
was compiled.
Any repair of components such as injection pump, alternator etc. ought to be left to our or the
manufacturer’s service department.
Best regards
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg Plant
We reserve the right to make technical modifications in the course of further development.
©2006 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, duplication or translation, in whole or in part, is not permitted without the written permission of
MAN. MAN reserves all rights accorded by the relevant laws on copyright.
MTDB Technical status: 01.2006 51.99598−8171

Instructions
2
Important instructions which concern technical safety and protection of persons are emphasised as shown
below.
Danger:
This refers to working and operating procedures which must be complied with in order to rule out
the risk to persons.
Caution:
This refers to working and operating procedures which must be complied with in order to prevent
damage to or destruction of material.
Note:
Explanatory descriptions which help in understanding the relevant work or operating procedure to
be carried out.
Fitting flat seals / gaskets
Flat seals / gaskets are often inserted with sealing agents or adhesives to make fitting them easier or to
achieve better sealing. Flat seals may slip in operation due to the “sewing-machine” effect, in particular if
they are used between parts with different rates of linear expansion under heat (e.g. aluminium and cast
iron), and leaks may then occur.
Example:
The cap of the front crankshaft seal. If a sealing agent or an adhesive is used here the flat seal will move
inwards in the course of time as a result of the different expansion rates of the materials. Oil will be lost, for
which the shaft seal may be thought to be responsible.
Flat seals / gaskets can be fitted properly only if the following points are observed:
DUse only genuine MAN seals / gaskets
DThe sealing faces must be undamaged and clean
DDo not use any sealing agent or adhesive −as an aid to fitting the seals a little grease can be used if
necessary so that the seal will stick to the part to be fitted
DTighten bolts evenly to the specified torque
Fitting round sealing rings
DUse only genuine MAN round sealing rings
DThe sealing faces must be undamaged and clean
DAlways wet round sealing rings with engine oil before fitting them

1
2
3
4
Instruction
3
Masking of fuel and lube oil pipe con-
nections (for classified engines only)
The unions of pressurised oil and fuel pipes are
masked with a protective tape.
If this tape is removed during a repair, the unions
must be masked with protective tape again after-
wards.
The following pipes are affected:
−Oil supply pipe to turbochargers
−Fuel pipes between supply pump, filter and
injection pump
−Injection pipes protected against leaks
Fig. 1
A protective tape is wound around the unions. En-
sure that there is 50 % overlap on every pass.
Figs. 2−4
The unions to be masked must be clean and free
of oil and grease.
Do not apply the protective tape unless this is the
case

Contents
4
Preface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type classification 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety regulations 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting table 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General notes on engine overhaul 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning after engine overhaul 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine views D 2842 LE 301 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine lubrication schedule 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic diagram of cooling system 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel diagram 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system
Checking and adjusting start of fuel delivery 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injection pump 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel injectors 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and repairing fuel injectors 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel prefilter 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and attaching fuel filter, exchanging filter cartridge 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system
Draining and filling coolant 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing thermostats 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant pump 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing coolant pump 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning cooling system 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing heat exchanger 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing pipe cluster for heat exchanger 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and repairing pipe cluster for heat exchanger 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning heat exchanger pipe cluster 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling and assembling seawater pump 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication
Changing oil filter 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the oil cooler 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing, repairing 2-gear-oil pump 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing, repairing 3−gear−oil pump 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil injection nozzle 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel / Crankshaft seal
Removing and fitting vibration damper, Replacing front crankshaft gasket 73. . . . . . . . . . . . . . . . . . . . .
Removing and installing flywheel, Replacing starter gear ring 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing crankshaft seal (flywheel end) 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the bearing race 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft seals 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake / exhaust system
Removing and installing intake pipes 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing exhaust pipe 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger, troubleshooting 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing turbocharger 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring axial / radial clearance of turbocharger shaft 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge pressure control valves 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing intercooler 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head
Removing and installing cylinder head 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting valve clearance 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
5
Cylinder head
Removing and installing rocker arms 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valves 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valve guides 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing valve seat insert 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reworking valve seat 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refacing valves 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve timing
Removing and installing the timing case 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the valve timing 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankgear, pistons
Removing and installing crankshaft 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing pistons with conrods 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing pistons from conrod and fitting, checking −replacing conrod 124. . . . . . . . . . . . . . . . . . . . . . .
Removing and installing piston rings 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing cylinder liners 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring piston protrusion 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attachments
Removing and installing starter motor 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and attaching alternator 134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing power take-off for hydraulic pump 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic speed control 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with GAC governor 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing speed pickup 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Data
Engine D 2840 LE 301 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine D 2842 LE 301 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder liner 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel and starter gear ring 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conrods 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conrod bearings 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head bolts (6kt- oder Torx-Kopf) 160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve springs 160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve gear 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve timing 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine lubrication 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system 166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power take-off for hydraulic pump 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque guide values 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine type classification
6
All the engines dealt with here are related in terms of their design and make up a family.
The type classification, which is made up of a series of letters and numbers, reveals some of the features
of the engine in question provided the reader is familiar with the underlying nomenclature.
The system is explained below using the model type D 2840 LE 301 as an example:
D The “D” at the start of the type classification stands for “Diesel”
28 The numbers “28” indicates that the power plant in question has a bore of 128 mm
4 The “4” means 142 mm stroke
0 The “0” indicates that there are 10 cylinders. If there is a “2”, this is a 12-cylinder engine
L This letter stands for “charge-air cooling” (German: Ladeluftkühlung)
E The “E” stands for “fitted engine” (German: Einbaumotor) and is intended to distinguish MAN
vehicle engines
301 This is a factory-internal development number

Safety regulations
7
General notes
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 persons, damage to property and
pollution. Additional information can be found in the operating instructions of the engine.
Important:
Should an accident occur despite all precautionary measures, particularly one involving contact with
corrosive acid, penetration of fuel under the skin, scalding by hot oil, antifreeze splashing into the eyes etc.
you must seek medical assistance immediately.
1. Regulations designed to prevent accidents with injury to persons
Checks, setting jobs and repair work must be carried out by authorised skilled personnel only.
DDuring installation work, switch off the battery master switch.
DWhen carrying out maintenance and repair work, ensure that the engine cannot be ac-
cidentally started from the bridge by unauthorised persons.
DThe engine must be started and operated only by authorized personnel.
DWhen the engine is running, do not get too close to the rotating parts.
Wear close−fitting working clothes
DDo not touch hot engine with bare hands: Risk of burns.
ËË
ËË
DKeep area surrounding engine, ladders and stairways free of oil and grease. Accidents
caused by slipping can have serious consequences
DOnly work with tools that are in perfect working order. Worn spanners/wrenches slip:
Danger of injury.
DPersons must not stand under an engine suspended on a crane hook. Keep lifting gear
in order.
DOpen the coolant circuit only when the engine has cooled down. If opening the coolant
circuit while the engine is hot is unavoidable, observe the instructions in the chapter
”Maintenance and care” in the Operator’s Manual.
DNeither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any
additional hydraulic oil circuit) during the operation. The fluids which flow out can cause
injury.

Safety regulations
8
DWhen working on the electrical system, first disconnect the earth cable of the battery
and reconnect this last to prevent short circuits.
DComply with the manufacturer’s instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.
DWhen performing welding work, observe the “Notes for welders”.
2. Regulations designed to prevent damage to engine and premature wear
DPrior to repairing the engine, clean it thoroughly. Ensure that dirt, sand or foreign matter will
not get into the engine during repair work.
DIf engine operation is disrupted, immediately determine the cause and have it remedied to prevent
additional damage.
DAlways use genuine MAN parts only. Installation of ”equally” good parts from other suppliers may cause
severe damage for which the workshop carrying out the work is responsible.
DNever allow the engine to run dry, i.e. without lubricant or coolant.
Appropriate notices must be attached to engines that are not ready for operation.
DToday modern components of diesel injection consist of high−precision parts which are exposed to
extreme stresses. The high−precision technology requires the utmost cleanliness during all work on
the fuel system.
Even a particle of dirt over 0.2 mm can lead to the failure of components.
DUse only MAN−approved service products (fuel, engine oil, anti−freeze and anti−corrosion agent). Pay
attention to cleanliness. Diesel fuel must be free of water.
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.
DControl and monitoring devices (charge control, oil pressure, coolant temperature) must be in perfect
working order.
DObserve the instructions for operating the alternator; see chapter ”Maintenance and care” in the
Operator’s Manual.

Safety regulations
9
3. Regulations designed to prevent pollution
Engine oil and filter elements / cartridges, fuel / fuel filter
DHand old oil over to old oil disposal companies only.
DTake strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
Caution:
Risk of contamination of potable water.
DFilter elements are classed as dangerous waste and must be treated as such.
Coolants
DTreat undiluted anti−corrosion agent and / or anti−freeze as dangerous waste.
DThe regulations of the respective local authorities must be observed when used coolant is disposed of.

Safety regulations
10
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 experiments. 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 in the appropriate manner.
−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.
∗Based on “Information sheet for handling used engine oil”.

Fault table
11
Operating faults and possible causes
We recommend
A repair is only complete when both the damage that occurred and the possible causes have been
eliminated. Finding out the cause of damage is often more difficult than repairing the damage that occurred.
We therefore recommend that you obtain a precise description of the operating fault before “removing and
dismantling” components. Then use a process of elimination (questions) to pinpoint the probable causes
and investigate and eliminate these successively on the basis of the table and your own experience. This
helps to reduce repairs to the required scale and to counteract claims regarding “over-eager” replacement
of parts and complaints about expensive work and down time.
Note:
The following list is conceived as an aid to memory for experts so that to causes of damage are overlooked
when dealing with faults. The precondition for this, however, is that the experts are familiar with the Repair
Manual for the engine as well as the accompanying Operating Instructions and the publication “Fuels,
Lubricants and Coolants for MAN Diesel Engines”.

Troubleshooting table
12
1. Starter turns over engine only slowly or not at all
2. Starter turns, engine does not start, engine does not start / difficult to start when cold
3. Engine stalls (dies) during operation, no longer starts (starter turns),
engine does not start / starts with difficulty when hot
4. Sudden, temporary engine shutdown, engine does not reach full revs
5. Engine only runs at idle speed, no throttle response
6. Engine only runs at increased idle speed, no throttle response
7. Rated engine speed distinctly reduced (even under no load)
8. Reduced output in all ranges
9. Irregular engine operation, traction loss
10. Unstable idle speed, engine hunting, misfiring, knocking in engine
11. Engine judder
12. Unusual combustion noise
13. Excessive smoke emission: White smoke / blue smoke
14. Excessive smoke emission: Black smoke
15. Engine temperature too high (coolant loss)
16. Intermediate speed control cannot be activated / does not switch off;
engine running at an excessively high speed
17. Fuel consumption too high
18. Lubricating oil pressure too low
19. Lubricating oil pressure too high
20. Lubricating oil consumption too high
21. Engine too “loud” / mechanical noise
Possible causes
x x Batteries discharged, battery lead connections loose or corroded,
break in power circuit
xCrank gear blocked
x x Starter solenoid switch sticks (clicks) / defective, cable connection loose or
damaged
x x Starter / starter interlock relay defective (carbon brushes worked loose / worn,
winding defective, short to ground)
x x x x Engine oil viscosity unsuitable, not suitable for ambient temperature, lubricating oil
quality does not correspond to specifications
x x Oil level in sump too high
xOil level in sump too low, oil in sump too thin (mixed with condensate or fuel)
xEngine temperature too high
xOil filter clogged
x x Oil pressure gauge defective
xSafety valve in oil circuit defective (does not close, spring fatigued or broken)
x x Bearing wear
xOil pump gears worn
xCrankshaft timing gears worn, tooth flank backlash too great
xx xEngine cold
xLubricating oil entering combustion chamber (piston rings worn, piston rings broken)
−valve stem guide worn −overpressure in crankcase (crankcase vent clogged)
xRelief valve in oil circuit defective (does not open), oil lines / oil galleries clogged
xLeaks in lubricating oil circuit, particularly at turbocharger and oil cooler
x x Piston rings heavily worn, broken
x x Piston pin or crankshaft bearing loose
xValve stems worn, bent
x x x Valve clearance not correct
x x Valves jam
x x x x Compression deficient, or more than 3−4 bar pressure difference between individual
cylinders
x x x Valve seats leaking
o x x Increased power intake due to defective secondary consumers such as
hydraulic pumps, fan etc., power take-off engaged
x x x x x Air cleaner soiled or clogged, turbo air system leaking,
air inlet / exhaust line clogged / leaking
x x x x x x x x x Fuel low pressure system: Fuel tank, prefilter, water trap faulty / clogged / mould / fungal
attack, fuel unsuitable / contaminated (paraffin added)
x x x x x x x x Fuel low pressure system: Fuel lines leaking, broken, clogged

Troubleshooting table
13
1. Starter turns over engine only slowly or not at all
2. Starter turns, engine does not start, engine does not start / difficult to start when cold
3. Engine stalls (dies) during operation, no longer starts (starter turns),
engine does not start / starts with difficulty when hot
4. Sudden, temporary engine shutdown, engine does not reach full revs
5. Engine only runs at idle speed, no throttle response
6. Engine only runs at increased idle speed, no throttle response
7. Rated engine speed distinctly reduced (even under no load)
8. Reduced output in all ranges
9. Irregular engine operation, traction loss
10. Unstable idle speed, engine hunting, misfiring, knocking in engine
11. Engine judder
12. Unusual combustion noise
13. Excessive smoke emission: White smoke / blue smoke
14. Excessive smoke emission: Black smoke
15. Engine temperature too high (coolant loss)
16. Intermediate speed control cannot be activated / does not switch off;
engine running at an excessively high speed
17. Fuel consumption too high
18. Lubricating oil pressure too low
19. Lubricating oil pressure too high
20. Lubricating oil consumption too high
21. Engine too “loud” / mechanical noise
Possible causes
x x x x x x x Fuel low pressure system: Air in system (turn on ignition when bleeding system)
x x x x x x x x x Fuel low pressure system: Fuel pump, overflow valve, main filter
x x x x x o x x Fuel high pressure system: Jets defective / clogged / leaking / coked
x x x x o Fuel high pressure system: Pressure lines −constriction, cavitation, leaking
x x o x x x x o Fuel high pressure system: Injection pump worn / set incorrectly
o x o o Fuel high pressure system: Injection pump constant-pressure control
valve / return flow restrictor defective
o o o x o x x x Injection pump-engine allocation: Start of delivery incorrect (basic installation),
start of delivery set incorrectly
x x x o Both rpm sensors defective, line defective
x x o x Exhaust turbocharger leaking or defective
x Turbine and compressor rotor in turbocharger dirty (out-of-balance, irregular running)
xIntercooler leaking, defective
x x Flame starter defective
xxRadiator dirty or failure of cooling system (temperatures too high)
xCoolant level too low, air in coolant circuit
xV-belt for water pump drive not tensioned correctly
x x Incorrect V-belt tension
xWater pump leaking, defective / Thermostat defective, does not open
xCoolant lines leaking, clogged or twisted
xCoolant entering combustion chamber (cylinder head / gasket leaking)
xEngine bearings worn

Notes
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General notes on engine overhaul
15
The service life of an engine is influenced by very different factors. It is therefore not possible to specify
certain fixed numbers of operating hours for general overhauls.
In our view, it is not necessary to open up and engine or perform a general overhaul as long as the engine
has good compression values and the following operating values have not changed significantly in relation
to the values measured on commissioning the engine:
DCharging pressure
DExhaust temperature
DCoolant and lubricant temperature
DOil pressure and oil consumption
DSmoke emissions
The following criteria greatly influence the length of the engine service life:
DCorrect power output setting according to the type of application
DTechnically correct installation
DInspection if installation by authorised personnel
DRegular maintenance as per maintenance plan
DChoice and quality of lube oil, fuel and coolant in accordance with the publication
“Fuels, Lubricants and Coolants for MAN Diesel Engines”

Commissioning after engine overhaul
16
Pressurisation
It is extremely important for internal combustion engines (following the completion of repair work, i.e. in
their dry state) to be pressurised with lube oil before being recommissioned. This procedure can also be
used for ascertaining damage and its causes.
If engines are not pressurised, the risk of premature damage to bearing surfaces is very high because it
takes a relatively long period of time for the lube oil drawn in from the oil pan via the oil pump to reach the
individual bearings.
Such incipient damage need not necessarily lead to immediate bearing failure, but may impair the proper
functioning of the bearings and reduce their service lives.
Diagram of the oil flow with unpressurised engines

Commissioning after engine overhaul
17
Pressurising an engine affords the following advantages:
DAll engine parts are lubricated before engine startup; a lubricating film can be built up inside the bear-
ings as early as after the first few rotations of the crankshaft, thereby preventing damage to the bearing
races
DAny loss of oil, be it the result of excessively large bearing play or leaks from the crankcase or from
crankcase bores which may not be plugged, can be detected immediately. For this purpose, mount the
engine on an assembly dolly, remove the oil pan and install a suitable oil collector under the crankcase
in such a way that the bearings are visible
Performance of pressurisation:
At least 30% of the total oil quantity is forced from the pressurisation container into the engine oil circuit.
The operating pressure serves as the yardstick for the pressure to be forced in and must not be exceeded.
The pressurisation container is connected up to the engine oil circuit at the oil filter (screw plug).

Engine views
18
Engine views D 2842 LE 301
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