Man D 0826 LE, Operating Instructions Manual

Page 1: ...Operating Instructions Diesel Engine D 0826 LE D 0826 LE 201...

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Page 3: ...iesel 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 ar...

Page 4: ...ent 20 Commissioning and operation Preparations 21 Starting 22 Running in 22 During operation 22 Shutting down 23 Temporary decommissioning of engines 23 Maintenance and care Engine lubrication 24 Fue...

Page 5: ...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 re late...

Page 6: ...d job number Order number Enter 14 digit engine serial number Enter 6 digit job number Or der number MAN Nutzfahrzeuge Aktiengesellschaft Typ Motor Nr Engine No NI II Temp C Werk N rnberg Germany MAN...

Page 7: ...th injury to persons During commissioning starting and operation D Before putting the engine into operation for the first time read the oper ating instructions carefully and familiarize yourself with...

Page 8: ...ize to ensure that the oil will not overflow D Open 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 th...

Page 9: ...ng aids e g injection with starting pilot D Use 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 wa...

Page 10: ...recautions to ensure that no oil or Diesel fuel gets into the drains or the ground The drinking water supply could be contaminated D Filter elements are classed as dangerous waste and must be treated...

Page 11: ...or wear protective gloves D Clean 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 hand...

Page 12: ...Technical information 10 Engine views D 0826 LE 1 2 3 4 5 6 7 8 9 10...

Page 13: ...Technical information 11 1 Fuel filter 2 Starter motor 3 Injection pump 4 Oil filter 5 Oil filler neck 6 Thermostat housing 7 Alternator 8 Oil drain plug 9 Oil dipstick 10 Turbocharger...

Page 14: ...uides For every two cylinders there is one cylinder head of high alloy cast iron Piston Conrod Crank assembly The integral die forged crankshaft is carried in seven bearings Balance of masses is by in...

Page 15: ...via an idler gear from the crankshaft 1 3 2 4 5 1 Crankshaft gear match marked with idler gear by D D 1 2 Idler gear 3 Camshaft gear match marked with idler gear by 2 2 2 4 Injection pump drive gear 5...

Page 16: ...l from the oil sump and delivers it through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings big end bearings and camshaft bearings as well as to the s...

Page 17: ...cleaned in a full flow oil filter with internal bypass valve Depending on the agreed extent of delivery and the design of the engine the lube oil cir cuit can be equipped with oil pressure monitors ad...

Page 18: ...the tank 1 6 5 4 2 3 1 Fuel tank 4 Injection pump 2 Fuel supply pump 5 Overflow restrictor 3 Fuel filter 6 Injector Injection pump The in line injection pump is driven from the crankshaft via gears I...

Page 19: ...s in fresh air and delivers it at a higher pressure to the cylinders The turbocharger is air cooled Lubrication of the main bearing is by oil under pressure from the engine lubricating system Air cool...

Page 20: ...The intercooler has to be removed from the engine for cleaning Cooling The engine has a liquid cooling system The water pump is a maintenance free impeller pump driven by V belts from the crank shaft...

Page 21: ...above all against moisture Operate the alternator according to the instructions given in the chapter Commis sioning and operation Starter motor The sliding gear starter motor is flanged to the rear of...

Page 22: ...visible on dipstick D After refilling with oil rotate the engine with the starter and move the shut down lever to stop at the same time until the oil pressure warning light goes out and the oil pressu...

Page 23: ...eriods without use press shut down lever in stop position and operate starter motor for a few sec onds max 10 until oil pressure is indicated Only then the engine should be started in the normal way R...

Page 24: ...aid connections with ground not even by briefly bringing the connections into contact D Do not operate the alternator without battery connection Shutting down Disengage the gearbox clutch and move the...

Page 25: ...Caution The oil is hot risk of scalding Do not touch the oil drain plug with bare fin gers Oil is an environmental hazard Handle it with care Refilling with oil Refill with fresh engine oil at the oil...

Page 26: ...extent by filling the tank as soon as the engine is switched off while the fuel tank is still warm formation of condensation is prevented Drain moisture from storage tanks regularly In stallation of...

Page 27: ...d Parallel fuel filter The fuel flows through two parallel filters 1 1 3 2 2 1 Filter element 2 Vent plugs 3 Moisture drain plugs Draining moisture Unscrew drain plugs at every oil change until moistu...

Page 28: ...er head Note for cleaning nozzles with Bosch cleaning set KDEP 2900 Clean nozzle body externally from soot and carbon When cleaning several nozzles at the same time make sure nozzle bodies and needles...

Page 29: ...hold your hands under the fuel jet as there is a risk of injury Do not inhale the atomised fuel If possible work under an extraction system Installation Clean seat in cylinder head Insert nozzle holde...

Page 30: ...um stances and fit a new one as soon as possible If in an exceptional case the coolant level has to be checked in an engine that has reached operating temperature first carefully turn the cap large ca...

Page 31: ...that water pump as follows a Drain coolant b Open thermostats positively use short circuit inserts so that the entire cool ant circuit is flushed in the cleaning operation c Fill coolant circuit with...

Page 32: ...dition will automatically lead to over heating of the engine with all of its accom panying effects For this reason it is rec ommendable to clean the tube bundle of the water to water heat exchanger at...

Page 33: ...er treatment Drained and spent cleaning and pickling fluid should be brought up to a pH value of 7 5 to 8 5 with the aid of caustic soda Once the precipitation has settled to the bottom of the contain...

Page 34: ...time to time To do this take compressor housing Cau tion do not tilt it so that it jams and clean it in solvent diesel oil petroleum ether using a brush If the air compressor should be badly fouled i...

Page 35: ...ly at turbine end A A Measuring point for dial gauge B A A Point of support for dial gauge tip B Measuring capacity Axial and radial clearances Gamme KKK axial mm radial mm D 0826 LE K 27 0 16 0 43 D...

Page 36: ...tor Ensure that the lid and the collector are reassembled correctly A lug on the collec tor fits into a recess in the edge of the lid If the filter is installed horizontally note the oben top marking...

Page 37: ...ent is avail able Blowing out wear goggles To do this fit a pipe to the compressed air gun The end of the pipe should be bent by approx 90 The pipe must be long enough to reach the bottom of the car t...

Page 38: ...iced changed the contamination gauge responds again immediately D if the main cartridge is defective When the main cartridge has been re moved the safety cartridge is accessible and can be removed als...

Page 39: ...move screw plug on governor hous ing If fitted take out blocking pin If the pointer is exactly in the centre of the inspection hole the pump plunger for cyl inder no 1 is at start of delivery However...

Page 40: ...elivery In this case turn the engine back and repeat the proce dure b Sleeve 9 15 12 11 3 29 13 15 30 If a light signal transmitter is not available good measurement results can also be achieved with...

Page 41: ...e re quired Set the engine so that the cylinder no 1 is at the specified number of degrees before firing top dead centre TDC Remove screw plug on governor housing The pointer for start of delivery mus...

Page 42: ...o be adjusted is at firing TDC This is the case when the valves of the synchronous pistons are just rocking Valve rocking on cylinder 1 5 3 6 2 4 6 2 4 1 5 3 Adjust valves on cylinder Cylinder head bo...

Page 43: ...olts completed Erster Nachzug der Zylinder kopfschrauben erledigt Spare part No 51 97801 0211 After the first 400 hours of operation re tighten cylinder head bolts 1 to 8 in the order shown in Tighten...

Page 44: ...thorized specialist personnel Bolts with hex head tightened by angle of rotation method only After the first 10 to 20 hours of operation after a repair turn the cylinder head bolts by a further 90 1 4...

Page 45: ...ep to 80 Nm D 3rd pretightening step to 150 Nm D 4th pretightening step turn by 90 D 5th pretightening step turn by 90 D Final tightening turn by 90 Adjust valve clearance Attach sticker 51 97801 0150...

Page 46: ...ins in its position Drive Tensioning forces according to the kg graduation on the tes ter Drive belt New installation When servicing width Installa tion After 10 min run ning time servicing after long...

Page 47: ...Notes 45...

Page 48: ...ing Intake opens 20 before TDC Intake closes 12 after BDC Exhaust opens 63 before BDC Exhaust closes 29 after TDC Fuel system Injection In line pump with flange fastening Governor All speed type Injec...

Page 49: ...r Generating Sets 21 5 l deep for Marine Propulsion 17 5 l standard 15 5 l shallow 12 5 l Oil pressure during operation depend ing on oil temperature oil viscosity class and engine rpm must by monitor...

Page 50: ...0 50 mm Valve timing Intake opens 20 before TDC Intake closes 12 after BDC Exhaust opens 63 before BDC Exhaust closes 29 after TDC Fuel system Injection In line pump with flange fastening Governor All...

Page 51: ...l standard 15 5 l Oil pressure during operation depend ing on oil temperature oil viscosity class and engine rpm must by monitored by oil pressure moni tors gauges Oil filter Full flow screw on type...

Page 52: ...27 Intercooler 19 L Lubricating oil filter 24 M Maintenance and care 24 37 Marking the dipstick 21 N Nameplates 4 O Oil cooler 15 Oil drainage 24 Oil level 24 P Piston Conrod Crank assembly 12 Prepara...

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Page 54: ...GB MAN Nutzfahrzeuge Aktiengesellschaft Vogelweiherstra e 33 D 90441 N rnberg Printed in Germany 51 99493 8251...