Man D2842 LE602 User manual

MAN Engines
A Division of MAN Truck & Bus
Operating Instruction
MAN Industrial Diesel Engines
D2842 LE602/604/606/607

Operating Instruction
MAN Industrial Diesel Engines
D2842 LE602/604/606/607
51.99493-8344 “Translation of the original operating instructions”
Version 03

Information and Copyright
2
Subject to technical alterations in the interests of further development.
The reprinting, reproduction or translation of this document, even in part, is not permitted without the
written permission of MAN. All rights under the law relating to copyright are expressly reserved by MAN.
©2014
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1932
Email: [email protected]
Internet: www.man-engines.com
Technical status: 01.2003
51.99493-8344

Contents
3
Page
Preface 4.................................................................................
Instructions 5..............................................................................
Nameplates 6.............................................................................
Safety regulations 7........................................................................
Commissioning and operation 12..............................................................
Engine views D 2842 LE 602 12............................................................
Engine views D 2842 LE 604 14............................................................
Engine views D 2842 LE 606 16............................................................
Engine views D 2842 LE 607 18............................................................
First commissioning 20....................................................................
Commissioning 21........................................................................
Starting 22..............................................................................
Operation monitoring system 23............................................................
Shutting down 23.........................................................................
Maintenance and care 24....................................................................
Lubrication system 24.....................................................................
Fuel system 27..........................................................................
Cooling system 29........................................................................
Air filter 30..............................................................................
V-belts 31...............................................................................
Turbocharger 33.........................................................................
Intercooler 33............................................................................
Starter motor 33..........................................................................
Alternator 33.............................................................................
Temporary decommissioning of engines 33..................................................
Technical data 34...........................................................................
Maintenance chart 42........................................................................
Troubleshooting table 44.....................................................................
Index 46...................................................................................

Preface
4
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 en
gine 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, trou
ble-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.
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 in the internet under:
https://mmrepro.mn.man.de/bstwebapp/BSTServlet
Best regards
MAN Truck & Bus AG
Nuremberg Plant

Instructions
5
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.

Nameplates
6
In all your correspondence please always quote engine model, serial number and job number (Order num
ber).
For this reason it is advisable to read off the data from the engine type plates before putĆ
ting the engine into operation and to enter them in the appropriate spaces.
The engine type plates are on the crankcase.
Model .................................................................
delivered on .................................................................
installed on .................................................................
Engine serial number .................................................................
Order number .................................................................

Safety regulations
7
General notes
Day-to-day use of power engines and the service products (fuels, lubricants, coolants) 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 sec
tions which contain the information necessary for preventing injury to persons, damage to property and pol
lution. 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 penetra
ting the skin, scalding from hot oil, anti-freeze being splashed in the eyes etc., consult a doctor immedia
tely.
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 operating 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
8
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 scalding. 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 sufficient size to en
sure 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 circuit 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
9
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 informa
tion 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 resulting from the in
stallation 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-corrosion 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 pressure, coolant tem
perature) function satisfactorily.
DComply with instructions for operation of the alternator. See “Maintenance and care".

Safety regulations
10
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 authorities.

Safety regulations
11
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, ir
ritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substan
ces 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 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
12
Engine views D 2842 LE 602
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Commissioning and operation
13
(1) Turbocharger
(2) Oil separator valve for crankcase breather
(3) Exhaust manifold
(4) Starter motor
(5) Oil sump
(6) Engine cranking device
(7) Cooling water pipe
(8) In take pipe
(9) Injection pump
(10) Alternator
(11) Oil drain plug
(12) Water pump
(13) Oil dipstick
(14) Oil filter
(15) Oil filler neck
(16) Air compressor

Commissioning and operation
14
Engine views D 2842 LE 604
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2
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Commissioning and operation
15
(1) Oil separator valve for crankcase breather
(2) Turbocharger
(3) Exhaust manifold
(4) Starter motor
(5) Oil sump
(6) Tension pulley
(7) Water pump
(8) Cooling water pipe
(9) Injection pump
(10) In take pipe
(11) Alternator
(12) Oil drain plug
(13) Oil filler neck
(14) Oil filter

Commissioning and operation
16
Engine views D 2842 LE 606
1
3
2
4
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2
12
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1
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7

Commissioning and operation
17
(1) Oil separator valve for crankcase breather
(2) Turbocharger
(3) Exhaust manifold
(4) Starter motor
(5) Oil sump
(6) Tension pulley
(7) Water pump
(8) Cooling water pipe
(9) Injection pump
(10) In take pipe
(11) Oil drain plug
(12) Oil filter
(13) Oil dipstick

Commissioning and operation
18
Engine views D 2842 LE 607
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7
1
2
3
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13
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1
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