Man Marine Diesel Engine D2848 D2840 D2842 LXE LE 401 To 413 Workshop Service Repair Manual

chodina@live.co.uk chodina@live.co.uk

Foreword 1 This Repair Manual is designed to facilitate proper repair of the engines listed here. 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 described in this Repair Manual. 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 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 on the Internet at: −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 manufacturer’s service department. Best regards MAN Nutzfahrzeuge Aktiengesellschaft Nuremberg Plant Since our products are in continuous development, we reserve the right to make technical modifications. © 2005 MAN Nutzfahrzeuge Aktiengesellschaft Reprinting, copying or translation, even of extracts, is not allowed without written permission from MAN. All rights under the copyright law are strictly reserved by MAN. MTDB Technical status: 08.2005 51.99493−8414 chodina@live.co.uk chodina@live.co.uk

Instruction 2 Important instructions concerning technical safety and personal protection are, as shown below, especially highlighted. 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. Assembly of pipes Danger: No pipes may be bent. Risk of breakage! Fitting flat seals / gaskets Gaskets are frequently used with sealants or adhesives as an aid to assembly or to achieve a better seal. Above all when parts with different levels of thermal expansion (e.g. aluminium and cast iron) are bonded, this can mean that the gasket is shifted during operation by the so-called stitching or sewing machine effect and leaks 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. Perfect assembly of gaskets can only be achieved if the following instructions are adhered to: D Use only genuine MAN seals / gaskets. D The sealing faces must be undamaged and clean. D Do 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. D Tighten bolts evenly to the specified torque. Assembly of round sealing rings D Use only genuine MAN round sealing rings. D The sealing faces must be undamaged and clean. D Always wet round sealing rings with engine oil before fitting them. chodina@live.co.uk chodina@live.co.uk

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 chodina@live.co.uk chodina@live.co.uk

Contents 4 Foreword 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruction 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trouble shooting table 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General information on the overhaul of engines 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning after engine overhaul 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views, D 2848 LE401 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views, D 2840 LE401 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views, D 2842 LE406 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross section of engine 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Longitudinal section of a D 2842 LE 401 engine 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of engine lubrication system 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of cooling system 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of fuel system 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system Checking and adjusting start of fuel delivery 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing injection pump 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel injectors 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and repairing fuel injectors 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning fuel prefilter 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing fuel filter cartridges 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system Draining and filling with coolant 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostats and water pump 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing water pump 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning cooling system 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heat exchanger 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pipe cluster for heat exchanger 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and repairing pipe cluster for heat exchanger 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning heat exchanger pipe set 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing impeller of raw water pump 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing raw-water pump 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Changing oil filter 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil cooler 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil pump 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil spray nozzle 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Removing and installing vibration damper, changing front crankshaft seal 79 . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel, replacing gear ring 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing crankshaft seal (flywheel end) 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchanging bearing race 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft seals 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake / exhaust system Removing and installing intake manifold 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining air filter 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing exhaust manifold with 8-hole-flange 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing exhaust manifold with 4-hole-flange 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger, trouble shooting 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the charge-air pressure 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . chodina@live.co.uk chodina@live.co.uk

Contents 5 Intake / exhaust system Checking axial and radial play of turbocharger rotor shaft 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Waste gates 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchanging charge-air pressure relief valve 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head Removing and installing cylinder head 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting valve clearance 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rocker arms 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valves 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valve guides 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing valve seat insert 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reworking valve seat 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refacing valves 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve timing Removing and installing timing case 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve timing 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing tachometer drive (angle drive) 129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankgear, pistons Removing and installing crankshaft 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing piston with connecting rod 135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detaching piston from and attaching to connecting rod checking - changing connecting rod 140 . . . . . . Removing, installing and changing piston rings 142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing cylinder liners 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring piston protrusion 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachments Removing and installing starter 148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-belts 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing power take-off for raw-water pump 152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing power take-off for hydraulic pump 156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system Coolant level probe 159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake air pre-heater 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmitters 162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools 165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . chodina@live.co.uk chodina@live.co.uk

Safety instructions 6 General notes This quick overview summarises important regulations and arranges them according to important aspects to provide the knowledge required to avoid accidents involving personal injury, damage to property and environmental damage. 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 corros- ive 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. D When carrying out maintenance and repair work, ensure that the engine cannot be accidentally started from the bridge by unauthorised persons. D The engine may only be started and operated by authorised personnel. D When the engine is running, do not get too close to rotating parts. Wear tight-fitting working clothes. D Do not touch the warm engine with your bare hands: danger of burns. D Keep the area round the engine, ladders and steps free of oil and grease. Accidents caused by slipping can have serious consequences. D Only work with tools that are in perfect working order. Worn spanners / wrenches slip: danger of injury. D Persons must not place themselves beneath an engine hanging on a crane hook. Keep lifting gear in order. D Only open the coolant circuit 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. D Neither pull nor open pipes and hoses that are under pressure (lubricant circuit, coolant circuit and possible downstream hydraulic oil circuit): danger of injury from outflowing fluids. D When checking the injection nozzles, do not hold your hands in the fuel jet. Do not inhale fuel mist. chodina@live.co.uk chodina@live.co.uk

Safety instructions 7 D When working on the electrical system, first disconnect the earth cable of the battery and reconnect this last to prevent short circuits. D Observe the manufacturer’s instructions for handling batteries. Caution: Battery acid is toxic and caustic. Battery gases are explosive. D When performing welding work, observe the “Notes for welders”. 2. Regulations designed to prevent damage to engine and premature wear D Prior to repairing the engine, clean it thoroughly. Ensure that dirt, sand or foreign matter will not get into the engine during repair work. D If engine operation is disrupted, immediately determine the cause and have it remedied to prevent additional damage. D Always 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. D Never 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. D Only use operating materials (fuel, engine oil, antifreeze and anticorrosion agents) approved by MAN. Ensure that everything is kept clean. Diesel fuel must be free of water. D Do not fill engine oil beyond the max. notch on the dipstick. Do not exceed the maximum per- mitted operating inclination of the engine. Non-observance can lead to severe engine damage. D Control and monitoring devices (charge control, oil pressure, coolant temperature) must be in perfect working order. D Observe the instructions for operating the alternator; see chapter “Maintenance and care” in the Operator’s Manual. chodina@live.co.uk chodina@live.co.uk

Safety instructions 8 3. Regulations designed to prevent pollution Engine oil and filter cartridges and elements, fuel / fuel filters D Old oil must be passed on for recycling. D Ensure without fail that oil and Diesel fuel will not get into the sewerage system or the ground. Caution: Danger of contaminating potable water! D Treat used filter inserts and cartridges as hazardous waste. Coolant D Treat undiluted corrosion protection agents and / or antifreeze as hazardous waste. D When disposing of used coolant, the regulations issued by the relevant local authorities must be ob- served. chodina@live.co.uk chodina@live.co.uk

Man Marine Diesel Engine D2848 D2840 D2842 LXE LE 401 To 413 Workshop Service Repair Manual

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