Man D 2840 LE 403 User manual

3
Operating Instructions –
MAN Marine Diesel Engines

4

Preface
5
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 book”.
Note:
All three publications belong to the engine and must always be kept ready to
hand near the engine in the engine room.
Comply in full with instructions relating to operation, prevention of accidents and
environmental 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
repair work.
Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Werk Nürnberg
Subject to change to keep abreast with technological progress.
2003 MAN Nutzfahrzeuge Aktiengesellschaft
No parts of this publication may be reproduced or translated without prior written permis-
sion of MAN. MAN explicitly reservs all rights according to copyright law.
MTDA Technical status: 04.2003 51.99493–8496

Instructions
6
Important instructions which concern technical safety and protection of persons are em-
phasised 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:
Explanations useful for understanding the working or operating procedure to be
performed.
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 “sew-
ing-machine” effect, in particular if they are used between parts with different rates of lin-
ear 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 ob-
served:
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

Contents
7
Page
Declaration 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplates 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety regulations 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning and operation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine views 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First commissioning 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation monitoring 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting down 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and care 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication system 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary decommissioning of engines 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting table 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For data see original declaration
If required this declaration is
enclosed with the delivery note.
Declaration
8
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-related 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 re-
cently amended by 93/44/EEC, or the latest amendment of said directive.
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33
D–90441 Nürnberg

Nameplates
9
In all your correspondence please always
quote engine model, serial number and job
number (Order number).
For this reason it is advisable to read off the
data from the engine type plates before
putting the engine into operation and to
enter them in the appropriate spaces.
The engine type plates are on the crank-
case (see illustration).
Model
......................................................................
delivered on
......................................................................
installed on
......................................................................
Engine serial number
......................................................................
Order 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
10
General notes
Handling diesel engines and the necessary resources is no problem when the per-
sonnel commissioned with operation and maintenance are trained accordingly
and use their common sense.
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.
DKeep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

Safety regulations
11
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”.
ËË
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
12
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”.
DDo not let the raw water pump run dry. If there is a risk of frost, drain the pump when
the engine is switched off.
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.

Safety regulations
13
DTake strict precautions to ensure that no oil or Diesel fuel gets into the drains or the
ground.
Caution:
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.
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”.

Commissioning and operation
14
Engine views D 2840 LE 403
1 2 3 4 5 6 7 8
910111213
8 7 6
918 17 16 15 14

Commissioning and operation
15
1 Heat exchanger and coolant surge tank
2 Relief valve on coolant surge tank
3 Intercooler
4 Coolant filler neck
5 Oil filler neck
6 Oil separator valve for crankcase breather
7 Air intake
8 Turbocharger
9 Exhaust pipe
10 Oil dipstick
11 Starter motor
12 Oil sump
13 Engine cranking device
14 Alternator
15 Water pump (engine coolant circuit)
16 Oil drain plug
17 Speed sender
18 Oil filter

Commissioning and operation
16
First commissioning
When putting a new or overhauled engine into operation for the first time pay attention to
the “Installation instructions for MAN marine diesel engines” without fail.
It is recommended that new or overhauled engines should not be operated at a load
higher than about 75% maximum load during the first few hours of operation. Initial run-in
should be at varying speeds. After this initial run-in, the engine should be brought up to
full output gradually.
Note:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”).
Otherwise the manufacturer’s warranty will become null and void.
Filling with fuel
Caution:
Fill the tank only when the engine is switched off. Pay attention to cleanliness.
Do not spill fuel.
Use only approved fuels (see “Fuels, Lubricants etc.”).
Filling-in of coolant
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze
agent on ethylene glycole basis or anti-corrosion agent.
See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.
DPour in coolant slowly via expansion tank, see page 57
DFor coolant filling quantity, see “Technical data”

Commissioning and operation
17
Raw water pump
Do not let raw water pump run dry.
Make sure that all valves / cocks in the
raw water circuit are open.
If there is a risk of frost, drain the raw wa-
ter pump.
Filling with engine oil
Caution:
Do not add so much engine oil
that the oil level rises above the
max. marking on the dipstick.
Overfilling will result in damage to
the engine.
The engines are as a rule supplied with-
out oil.
Pour oil into engine via filler neck (arrow),
see page 51.
For the quantity required see “Technical
Data”.

Commissioning and operation
18
Commissioning
Before daily starting the engine, check fuel level, coolant level and engine oil level and
replenish, if necessary.
Note:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”).
Otherwise the manufacturer’s warranty will become null and void.
Checking oil level
Check engine oil level only approx.
20 minutes after the unit has been
switched off.
DPull out dipstick (arrow)
Dwipe it with a clean, lintfree cloth
Dand push it in again up to the stop
DPull out dipstick again
The oil level should be between the two
notches in the dipstick and must never fall
below the lower notch. Top up oil as nec-
essary.
Caution:
Do not add so much engine oil
that the oil level rises above the
max. marking on the dipstick.
Overfilling will result in damage to
the engine.
Ensure outmost cleanliness when han-
dling fuels, lubricants and coolants.
Oil
?
MIN
MAX

Commissioning and operation
19
Starting
Danger:
Before starting make sure that no-one is in the engine’s danger area.
Caution:
When starting do not use any additional starting aids (e.g. injection with starting
pilot).
Ensure that the gearbox is in neutral.
Insert starter key and turn it to position “I”. The check lamp comes on to show that the
engine is ready for operation.
Turn starter key further to position “II” (pre-glow). The display lamp (usually in the driver’s
station) comes on.
After the pre-glow period the display lamp begins to flash. This signalizes that the engine
is ready for starting.
Note:
If the engine is not equipped with a pre-glowing function, immediately turn the
starter key through to position “III”.
Turn key further up to the stop (position “III”). The display lamp goes out. The starter mo-
tor is actuated.
Lube oil pressure must build up at the oil pressure gauge. If it does not, switch off the en-
gine immediately.
Do not operate starter for longer than 10 seconds at a time.
After ignition of the engine, release the starter button and adjust control lever for desired
speed.
If engine fails to start, release the key, wait about 30 seconds, then operate starter again.
For repeated starting turn the key back to OFF.
If the engine is kept idling for long periods it may cool down and thus start to emit white
or blue smoke.
We therefore recommend that you do not let the engine idle for more than 5 minutes.
It is well known that with any internal combustion engine wear is higher during idling.
Idling for longer periods is also an environmental nuisance.

Commissioning and operation
20
Operation monitoring
The D 2840 LE 403 / D 2842 LE 404 is equipped as series standard with a monitoring
and diagnostic system MMDS.
On the control console and alternatively on other control stands, the following display de-
vices are available for monitoring operation:
1. Analog round instruments, see below
2. Display device MMDS-L, see page 21
3. Display device MMDS-LC, see page 23
4. Engine room panel MMDS-EP, see page 31
For operation and speed adjustment, MAN provides the following equipment:
5. Drive lever control system Mini Marex made by Mannesmann-Rexroth, see page 32
6. Optional: Emergency unit Em, see page 42
1. Round instruments
MAN can supply the following VDO round instruments for operation monitoring:
Revolution counter with integrated digital hours of operation counter
Oil pressure engine 0–6 bar
Oil pressure gearbox 0–25 bar
Oil temperature engine 50–150°C
Coolant temperature engine 40–120°C
Exhaust temperature engine 100–900°C
Voltmeter 18–32 V