Man D2842 LE602, Operating Instructions Manual

Page 1: ...MAN Engines A Division of MAN Truck Bus Operating Instruction MAN Industrial Diesel Engines D2842 LE602 604 606 607...

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Page 3: ...Operating Instruction MAN Industrial Diesel Engines D2842 LE602 604 606 607 51 99493 8344 Translation of the original operating instructions Version 03...

Page 4: ...ent 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 Vogelweiherstra e 33 90441 N...

Page 5: ...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...

Page 6: ...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...

Page 7: ...s 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...

Page 8: ...umber Order num ber For this reason it is advisable to read off the data from the engine type plates before put ting the engine into operation and to enter them in the appropriate spaces The engine ty...

Page 9: ...D Before 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...

Page 10: ...ircuit 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 D Neither tighten up nor...

Page 11: ...ing aids e g injection with starting pilot D Use 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 wa...

Page 12: ...precautions 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 13: ...c 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 han...

Page 14: ...Commissioning and operation 12 Engine views D 2842 LE 602 5 4 3 1 2 7 8 6 14 11 12 3 1 2 15 10 10 9 8 16 13...

Page 15: ...lve 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...

Page 16: ...Commissioning and operation 14 Engine views D 2842 LE 604 5 3 4 2 1 6 8 7 10 1 2 11 10 9 12 13 3 14...

Page 17: ...tor 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 d...

Page 18: ...Commissioning and operation 16 Engine views D 2842 LE 606 1 3 2 4 6 8 5 8 9 10 2 12 3 1 10 11 13 7...

Page 19: ...il 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...

Page 20: ...Commissioning and operation 18 Engine views D 2842 LE 607 6 7 1 2 3 4 5 13 9 1 2 3 12 8 9 11 10...

Page 21: ...l separator valve for crankcase breather 2 Turbocharger 3 Exhaust manifold 4 Starter motor 5 Oil sump 6 Tension pulley 7 Cooling water pipe 8 Injection pump 9 In take pipe 10 Oil drain plug 11 Water p...

Page 22: ...ling 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 brochure Fuels lubricants etc Filling in of coolant...

Page 23: ...al but only if at least 20 minutes have passed since the ma chine was switched off D Pull out dipstick D wipe it with a clean lintfree cloth D and push it in again up to the stop D Pull out dipstick a...

Page 24: ...Triggering of flame start system D Starting procedure initiated after preglowing start assistance and interrupted after engine starts at ap prox 300 400 rpm D Should the engine not start starting tim...

Page 25: ...the oil pressure of the engine lubrication and coolant agent temperature during operations If the monitoring equipment displays a drop in the pressure of lubrication oil or excess coolant temperature...

Page 26: ...er The oil is hot risk of scalding Do not touch the oil drain plug with bare fingers Oil is an environmental hazard Handle it with care With the engine at operating temperature remove the oil drain pl...

Page 27: ...and let it run for a few minutes at low speed Caution If no oil pressure builds up after approx 10 seconds switch off the engine imme diately Check oil pressure and check that there is no oil leakage...

Page 28: ...opened Risk of burns and scalds D After releasing the clamping bolts remove filter bowls D Renew filter cartridges Thoroughly clean all other parts in cleaning fluid do not allow cleaning fluid to ent...

Page 29: ...No alterations must be made to the injection pump If the lead seal is damaged the warranty on the engine will become null and avoid Faults We urgently recommend that you have faults in the injection p...

Page 30: ...m D Check filter for leaks Caution Used fuel filters are classed as dange rous waste and must be disposed of ac cordingly Bleeding the fuel system Note To bleed the fuel system switch on the ignition...

Page 31: ...nly when engine has cooled down Fill the cooling system of the engine with a mixture of drinkable tap water and anti freeze agent on the ethy lene glycole basis or anti corrision agent See Publication...

Page 32: ...cing depend on the specific operating conditions en countered Clogged air filters may cause black smoke and reduce power A check should be made from time to time to see that the fastening elements sec...

Page 33: ...heard to disengage This will cause the indica tor to move upwards If pressure is maintained after the spring has disengaged a false reading will be obtained Reading of tension D Read of the tensionin...

Page 34: ...or bottom left D Remove fixing bolts 1 D Remove lock nut 2 D Adjust nut 3 until V belts have correct tensions D Retighten lock nut and fixing bolts To change the V belt turn back the setting nut and s...

Page 35: ...rical system Connect up the earth cable last as there is otherwise a risk of short circuits Alternator The alternator is maintenance free Nevertheless it must be protected against dust and above all a...

Page 36: ...ameplate Firing order 1 12 5 8 3 10 6 7 2 11 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 60 mm Valve timing Intake opens 24 before TDC Intake closes 36 after BDC Exhaust opens 63 before B...

Page 37: ...3 l Oil pressure during operation depending on oil temperature oil viscosity class and engine rpm must be monitored by oil pressure monitors gau ges Oil filter Full flow filter with two paper filter e...

Page 38: ...Rating see engine nameplate Firing order 1 12 5 8 3 10 6 7 2 11 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 60 mm Valve timing Intake opens 24 before TDC Intake closes 36 after BDC Exhaus...

Page 39: ...low 53 l Oil pressure during operation depending on oil temperature oil viscosity class and engine rpm must be monitored by oil pressure monitors gau ges Oil filter Full flow filter with two paper fil...

Page 40: ...Rating see engine nameplate Firing order 1 12 5 8 3 10 6 7 2 11 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 60 mm Valve timing Intake opens 24 before TDC Intake closes 36 after BDC Exhaus...

Page 41: ...filter Shallow 53 l Oil pressure during operation depending on oil temperature oil viscosity class and engine rpm must be monitored by oil pressure monitors gau ges Oil filter Full flow filter with tw...

Page 42: ...Rating see engine nameplate Firing order 1 12 5 8 3 10 6 7 2 11 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 60 mm Valve timing Intake opens 24 before TDC Intake closes 36 after BDC Exhau...

Page 43: ...filter Shallow 53 l Oil pressure during operation depending on oil temperature oil viscosity class and engine rpm must be monitored by oil pressure monitors gau ges Oil filter Full flow filter with tw...

Page 44: ...position and if necessary retighten D D Service the air cleaner earlier if severe operating conditions demand it D 2nd retightening of cylinder head bolts with new or overhauled en gine D Check and if...

Page 45: ...604 606 607 200 h 200 h 400 h 400 h See Publication Fuels Lubricants and Coolants for MAN Diesel Engines Note D Use only approved engine oils D Where Diesel fuels with a sulphur content greater than...

Page 46: ...tarter solenoid switch defective D D D D D Start of delivery not correct incorrectly set D Injection nozzles clogged D Internal damage to engine D D D Fuel quality not in accordance with specification...

Page 47: ...olant pipes leaking blocked or twisted D Oil level in sump too low D Engine temperature too high D Oil filter clogged D D Oil pressure gauge defective D D Selected oil viscosity not suitable for ambie...

Page 48: ...mmissioning 20 Fuel filter 28 Changing fuel filter 28 Fuel system 27 I Injection pump 27 Intercooler 33 L Lubrication system 24 M Maintenance and care 24 Maintenance chart 42 N Nameplates 6 O Operatio...

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