Man D 2848 LE 401 User manual

D 2848 LE 401 / 403 / 405
D 2840 LE 401 / 402 / 407
D 2842 LE 401 / 402 / 403 / 406 / 408 / 411 / 412 / 413

Preface
5
Dear Customer,
these Operating Instructions are intended to familiarize you with your new MAN Diesel
engine and how it operates.
This manual contains information on “Fuels, Lubricants and Coolants for MAN Diesel En-
gines”.
This manual is supplemented by the publication “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.
Note:
Only use fuel, coolants and lubricants in accordance with MAN’s regulations
otherwise the manufacturer’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−
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.
©2006 MAN Nutzfahrzeuge Aktiengesellschaft
No parts of this publication may be reproduced or translated without prior written permis-
sion of MAN. MAN explicitly reserves all rights according to copyright law.
MTDB Technical status: 03.2006 51.99493−8498

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
Preface 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplates 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety regulations 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning and operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine views D 2842 LE 401 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First commissioning 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation monitoring system BE1 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting down 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and care 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication system 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary decommissioning of engines 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting table 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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
recently amended by 93/44/EEC, or the latest amendment of said directive.
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33
D−90441 Nürnberg

Declaration
9

Nameplates
10
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
11
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
DFor safety reasons a separate, functioning red emergency-stop-
button for each engine must be installed at every bridge (the engine
must stop immediately when the button is pressed once).

Safety regulations
12
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.
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
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.

Safety regulations
13
DComply with the manufacturer’s instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.
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.

Safety regulations
14
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.
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 −

Safety regulations
15
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
16
Engine views D 2842 LE 401
12 3
91011
7
456
8 12
1413
15
1718 1619

Commissioning and operation
17
1 Heat exchanger and coolant surge tank
2 Coolant filler neck
3 Intercooler
4 Relief valve on coolant surge tank
5 Oil filler neck
6 Air intake
7 Water pump (engine coolant circuit)
8 Oil drain plug
9 Oil dipstick
10 Starter motor
11 Exhaust pipe, liquid-cooled
12 Waste Gate
13 Turbocharger, liquid-cooled
14 Oil separator valve for crankcase breather
15 Engine cranking device
16 Oil sump
17 Oil cooler
18 Connection for oil pressure sensor
19 Oil filter

Commissioning and operation
18
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.”)
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 52
DFor coolant filling quantity, see “Technical data”

Commissioning and operation
19
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 46.
For the quantity required see “Technical
Data”.
Oil

Commissioning and operation
20
Commissioning
Before daily starting the engine, check fuel level, coolant level and engine oil level and
replenish, if necessary.
Caution:
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
21
Starting
Danger:
Before starting make sure that no-one is in the engine’s danger area.
Ensure that the gearbox is in neutral.
Caution:
When starting do not use any additional starting aids (e.g. injection with starting
pilot).
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.
For cold engines (<20°C) move control lever into starting position (against stop for maxi-
mum engine speed).
Note:
When starting the cold engine (control lever in starting position) retract the control
lever as quickly as possible into lower idling position after the engine has
started.
The warm engine can also be started with the control lever in idling position.
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.

Commissioning and operation
22
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.
Caution:
Do not overload the engine. Do not exceed the maximum permissible engine tilt.
If faults occur, find their cause immediately and have them eliminated in order to
prevent more serious damage!
Display panel in the engine room. Func-
tions independently of the BE1 operation
monitor and shows analog operating val-
ues from the engine.
During operation the oil pressure in the
engine lubrication system must be moni-
tored. If the monitoring devices register a
drop in the lube oil pressure, switch off the
engine immediately.
Operation monitoring system BE1
Caution:
If an engine / gear box alarm is displayed on the monitoring device, the engine is
to be turned off, i.e. operated at low-pressure at a max. of 1200 rpm.
When following alarms are activated
−engine oil pressure / reduction of lubrication oil pressure
−engine coolant temperature / overheating of engine coolant
−engine charge-air temperature
the engine is to be turned off immediately and the cause of the error properly
remedied, i.e. in a specialist workshop.
Do not put this engine into operation again until the error has been eliminated.