Man D 2842 le 409 Operating instructions

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Preface

This Repair Manual is designed to facilitate competent repair of the engines listed here in.

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

The pictures and relevant 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.

Please note that all jobs described in this Repair Manual were carried out on an engine which was not in-

stalled.

The expert knowledge necessary for handling Diesel engines was taken for granted when this publication

was compiled.

Note:

Only use fuel, coolants and lubricants in accordance with MAN’s regulations otherwise the manu-

facturer’s warranty 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 in the internet under:

http://www.man-mn.com/ "Products & Solutions "E-Business

Any repair of components such as injection pump, alternator etc. ought to be left to our or the manufactur-

er’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, 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.

MTDB Technical status: 03.2006 51.99598−8081

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Instructions

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:

Explanations useful for understanding the working or operating procedure to be performed.

Assembly of pipes

Danger:

No pipes may be bent.

Risk of breakage!

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 toric seals

DUse only genuine MAN toric seals

DThe sealing faces must be undamaged and clean

DAlways wet toric seals with engine oil before fitting them

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Contents

Preface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic knowledge 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault table 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General notes on engine overhaul 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning after engine overhaul 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine views 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic diagram of engine lubrication system 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic diagram of cooling system 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic diagram of fuel system 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intercooling system 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system

Checking and setting start of fuel delivery 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing injection lines 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing injection pump 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing injection nozzles 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking injection nozzles 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel prefilter 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and attaching fuel filter, exchanging filter cartridge 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system

Draining and filling coolant 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing thermostats 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing coolant pump 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing coolant pump 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning cooling system 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing heat exchanger 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing pipe cluster for heat exchanger 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking and repairing pipe cluster for heat exchanger 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning heat exchanger pipe cluster 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing impeller of sea water pump 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing sea water pump 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication

Changing oil filter 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing the oil cooler 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing, repairing oil pump 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil injection nozzle 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel / Crankshaft seal

Removing and fitting vibration damper, replacing front crankshaft gasket 76. . . . . . . . . . . . . . . . . . . . . .

Removing and installing flywheel, replacing starter gear ring 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing crankshaft seal (flywheel end) 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the bearing race 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft seals 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake / exhaust system

Removing and installing air filter 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing intake pipes 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing exhaust pipe 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger, troubleshooting 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing turbocharger 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring axial / radial clearance of turbocharger shaft 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Waste gates 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .