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Maintenance and Care

MAN-Industrial diesel engines D2842 LE103

Carefully read the Operating Instructions before starting any work!

This is especially valid for the chapter on General Safety Instructions

and the safety instructions in each of the chapters.

8.4.7

Air filter

IMPORTANT!

Engine damage due to contaminated combustion air!

The entry of unfiltered air can lead to greatly increased cylinder and piston wear.

For this reason:

Always operate the engine with the air filter fitted.

Regularly check the connection elements between the air filter and the engine for sealing.

An air filter must be fitted by the vehicle manufacturer to clean the intake air.

The maintenance interval for the air filter depends on the operating conditions that exist. Dirty air filters can
lead to black exhaust smoke and a reduction in power.

Summary of Contents for D2842 LE103

Page 1: ...Operating Instructions MAN Industrial Diesel Engines D2842 LE103 51 99493 8579 Translation of the original operating instructions...

Page 2: ...bject to technical alterations in the interests of further development Reprinting copying or translation even of extracts is not allowed without written permission from MAN All rights under the copyri...

Page 3: ...r Applicable Documents 9 1 6 Spare Parts 10 1 7 Disposal 10 1 8 Warranty Terms 11 1 9 Service 11 2 General Safety Instructions 13 2 1 Intended Use 13 2 2 Contents of the Operating Instructions 14 2 3...

Page 4: ...ngine Views 28 4 2 1 Front Right View 28 4 2 2 Front Left View 29 5 Transport Packaging and Storage 31 5 1 Prerequisite 31 5 2 Safety Instructions 31 5 3 Transport Inspection 33 5 4 Transport 34 5 5 P...

Page 5: ...ngine Oil 45 7 4 Operation 46 7 4 1 Monitoring Operation 46 7 4 2 Starting Engine 46 7 4 3 Engine Shut Off 46 7 4 4 Stopping in an Emergency 46 8 Maintenance and Care 47 8 1 Prerequisite 47 8 2 Safety...

Page 6: ...ns 71 10 3 Temporary Decommissioning of Engines 72 10 4 Recommissioning of Decommissioned Engines 73 10 4 1 Commissioning of Preserved Engines according to MAN Werknorm works standard M 3059 73 10 4 2...

Page 7: ...rove environmental protection This begins with the development and design of our engines We make sure that no environmentally hazardous materials are used and for ex ample that the emissions fulfil th...

Page 8: ...hazardous situation which leads to death or serious injuries if not avoided WARNING indicates a possible hazardous situation which can lead to death or serious injuries if not avoided CAUTION indicat...

Page 9: ...ions may deviate from what is described and illustrated in these instructions Valid are the commitments agreed upon in the delivery contract and the General Terms and Conditions of MAN and the law app...

Page 10: ...tablished For other products despite on going market observations we cannot provide an assessment and therefore cannot vouch for them WARNING Risk of injury from incorrect spare parts Incorrect or fau...

Page 11: ...to this operating instruction and if included supplier operating instructions renders claims under the warranty null and void The use of non approved parts leads to the loss of warranty claims We reco...

Page 12: ...l diesel engines D2842 LE103 12 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions i...

Page 13: ...use also includes compliance with the prescribed operating maintenance and repair work The engine may only be used maintained and repaired by persons who are familiar with the engine and have been inf...

Page 14: ...S The operator must be knowledgeable about the valid occupational health and safety regulations and be able to assess in a risk analysis the dangers that are present in the specific working conditions...

Page 15: ...rming work on electrical systems due to his her technical education training know ledge and experiences as well as knowledge of the respective standards and regulations and can recog nise and avoid an...

Page 16: ...h with narrow sleeves and with no pro truding parts It is used primarily to protect against injury weather and dirt No rings bracelets necklaces and other jewellery are to be worn while working Protec...

Page 17: ...lified electrician S When working on the electrical system the power supply must be switched off and then properly checked to ensure no electrical current is present S Before starting any maintenance...

Page 18: ...person in charge S In the case of fire immediately stop working Leave hazard area until the danger is over Coolants Antifreeze Anticorrosion Agents WARNING Risk of injury caused by coolants that are...

Page 19: ...of noise occurring in the working area can cause serious damage to hearing For this reason S Always wear hearing protection when working S Do not unnecessarily remain in the hazard area Leave hazard a...

Page 20: ...situations to people and property are avoided in case the its power supply is interrupted or is turned back on after an interruption The emergency off equipment must always be freely accessible WARNI...

Page 21: ...with the emergency first aid and rescue equipment S Carry out regular instruction on safety measures S Always keep access lanes for rescue vehicles free of any obstructions In the case of an accident...

Page 22: ...injury caused by illegible symbols In the course of time stickers and symbols become dirty or unrecognisable for other reas ons For this reason S Always keep the safety warning and operational signs i...

Page 23: ...ased into the environment immediately take suitable measures to minimise this If in doubt inform the responsible local authorities The following environmentally hazardous substances are used Lubricant...

Page 24: ...Industrial diesel engines D2842 LE103 24 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instr...

Page 25: ...ters 3 Engine Model Plate For all communications please always give the en gine model 3 engine number 4 and work num ber job number 5 Therefore before the initial start up of the engine read and note...

Page 26: ...Engine No Class identifier assignment 711 Model number according to index of model codes 1234 Day of assembly plant internal 547 Assembly order sequence number on day of assembly 3 2 Explanation of M...

Page 27: ...ain flow Aux iliary equipment such as series high pressure pumps turbochargers and power take offs are connected to the engine lubrication oil circuit Cooling System The cooling circuit takes the form...

Page 28: ...ctions and the safety instructions in each of the chapters 4 2 Engine Views 4 2 1 Front Right View 1 2 3 4 5 6 7 9 10 11 8 1 Combustion air line to the charge air cooler 2 Combustion air line from the...

Page 29: ...id for the chapter on General Safety Instructions and the safety instructions in each of the chapters 4 2 2 Front Left View 1 2 3 4 5 6 7 8 9 10 11 1 Turbocharger 2 Oil separator valve for crankcase v...

Page 30: ...strial diesel engines D2842 LE103 30 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructi...

Page 31: ...e the General Safety Instructions and the safety information in this chapter Strictly observe these instructions and act prudently to avoid accidents personal injury and property damage Personal Prote...

Page 32: ...h a crane the packages can swing out and cause seri ous injuries and significant property damage For this reason S Ensure that during the transport of packages no persons objects or obstacles are in t...

Page 33: ...or missing items and for damage from transport If external signs of transport damage are apparent S Do not accept delivery or only accept under written protest S List scope of damage on the transport...

Page 34: ...and the safety instructions in each of the chapters 5 4 Transport Lifting Points There are 2 lifting lugs 1 and 2 for the crane installed on the engine WARNING Risk of death caused by the load falling...

Page 35: ...fting equipment according to the picture 2 Ensure that the package is hanging straight or compensate for the off centre point of gravity 3 Start the transport Transport with Forklift The engine can be...

Page 36: ...rrect disposal Packaging materials are valuable raw materials and can in many cases continue to be used or can be processed and recycled Incorrect disposal of packaging materials may cause an environm...

Page 37: ...ualified personnel with sufficient experi ence Faulty installation can cause life threatening situations and considerable property damage For this reason S Installation and commissioning are only to b...

Page 38: ...ency off button for shutting down the system or engine in an emergency must be installed for each engine For this reason S Install an emergency stop button to shut down the system in an emergency S Ch...

Page 39: ...ed fluids and lubric ants Liability for material defects is terminated if non approved fluids and lubricants are used For this reason S Only use approved fluids and lubricants see Fluids and Lubricant...

Page 40: ...ubricants publication 1 Fill cooling fluid according to the instructions of the manufacturer of the complete system 2 Fill cooling fluid slowly max 10 ltr min 6 4 3 Filling Engine Oil IMPORTANT Termin...

Page 41: ...performed by instructed personnel or by trained qualified person nel Ground Rules WARNING Danger caused by faulty operation Improper operation can cause serious personal injury or considerable proper...

Page 42: ...engine If necessary refill diesel fuel coolant and oil IMPORTANT Termination of liability for material defects by use of non approved fluids and lubric ants Liability for material defects is terminate...

Page 43: ...filling Do not let coolant leak out onto the ground or into sources of water otherwise this will cause damage to the environment IMPORTANT Engine damage caused by excessive temperature difference When...

Page 44: ...oil level when the engine is horizontal and only after at least 20 minutes have passed since the engine was switched off 1 Pull out oil dipstick 1 2 Wipe off oil dipstick with a lint free cloth 3 Rei...

Page 45: ...ability of material defects is terminated if non approved fluids and lubricants are used For this reason S Only use approved fluids and lubricants see Fluids and Lubricants publication IMPORTANT Compo...

Page 46: ...n with Startpilot 1 Unload the engine before start up e g uncouple switch off load set to idle etc 2 switch on EDC 3 Initiation of the flame primer system 4 Initiation of the start sequence after term...

Page 47: ...he operating instruction must only be carried out by trained specialist personnel Ground rules WARNING Risk of injury caused by improperly performed maintenance Improper maintenance can case serious i...

Page 48: ...oaks into the ground Risk of contaminating drinking water Carefully collect used oil and properly recycle When handling used oil observe the safety measures to protect your health Filter Elements S Fi...

Page 49: ...1 D Clean fuel prefilter D D D Check and if necessary adjust valve clearance D D D Maintain clean replace air filter 1 D D Change engine oil and oil filter 2 D D D Injection nozzles Removal and insta...

Page 50: ...engine oil change Drain engine oil Drain engine oil with engine at operating temperature NOTE Use a container with sufficient ca pacity to change oil at least 10 litres This ensures that oil will not...

Page 51: ...e filter bowl 4 after loosening the fixing screw 3 3 Replace filter insert 5 Thoroughly clean all remaining parts in cleaning fluid NOTE To prevent the sealing ring 6 from turning hold filter bowl 4 w...

Page 52: ...damage caused by over filling Engine damage can occur if engine oil is filled to above the max mark on the oil dipstick For this reason S Do not fill engine oil above the max mark on the oil dipstick...

Page 53: ...e oil level when the engine is horizontal and only after at least 20 minutes have passed since the engine was switched off 1 Pull out oil dipstick 1 2 Wipe off oil dipstick with a lint free cloth 3 Re...

Page 54: ...fuel 1 Close shutoff valves between engine and tank 2 Unscrew filter housing 1 3 remove O ring 2 from the filter housing 1 4 Wash out filter housing 1 and gauze filter 3 in clean diesel fuel and blow...

Page 55: ...Instructions and the safety instructions in each of the chapters 8 4 3 Fuel Filter Drain Condensation DANGER Fire hazard caused by uncontrolled fuel leakage When opening the fuel system fuel can leak...

Page 56: ...uel system fuel can leak out uncontrolled For this reason S Work carefully S Do not spill any fuel 1 Close shutoff valves between engine and tank 2 Open drain screw 4 3 Drain fuel into suitable contai...

Page 57: ...olled For this reason S Work carefully S Do not spill any fuel The filter head has an arrow marking the direction of fuel flow 1 Switch on ignition 2 Unscrew bleed screw 1 of first filter in the di re...

Page 58: ...coolant spill while draining Do not let coolant leak out onto the ground or into wa ter sources because this will damage the environment 1 Briefly open the closing cover on the filling neck of the ex...

Page 59: ...e When topping up with cold coolant in an engine that is hot after operation there is a risk of damage to the engine due to the high temperature difference For this reason S Coolant to be added must b...

Page 60: ...ated combustion air The entry of unfiltered air can lead to greatly increased cylinder and piston wear For this reason S Always operate the engine with the air filter fitted S Regularly check the conn...

Page 61: ...e in the middle between the two V pulleys such that the edge of the contact surface 3 fits closely along the side of the V Belt 3 Apply pressure slowly and at right angles to the surface of the pressu...

Page 62: ...apter on General Safety Instructions and the safety instructions in each of the chapters Tension and replacement of V Belt 1 Loosen fixing bolts 1 2 Loosen lock nut 2 3 Reset adjuster nut 3 until the...

Page 63: ...rty For this reason S Before commencing work on electrical equipment first make sure that the battery ground cable is disconnected S When restoring the connections leave the ground cable till last Ins...

Page 64: ...ustrial diesel engines D2842 LE103 64 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instruct...

Page 65: ...r Strictly observe these instructions and act prudently to avoid accidents personal injury and property damage 9 2 Safety Instructions Personnel S Engine faults may only be rectified by specially trai...

Page 66: ...D Set transmission shift lever to N D Replace faulty fuses D Repair any loose corroded and broken wires and contacts D See information at Starter D Remove objects that interfere with the movement of t...

Page 67: ...el feed pump worn or faulty D Check whether the guide tube is correctly installed and the cor rect oil dipstick is being used D If coolant or fuel is discovered in the engine oil check cylinder head g...

Page 68: ...If coolant or fuel is discovered in the engine oil check cylinder head gasket cylinder liner gas ket and piston rings Fuel consumption too high D Fuel grade does not meet the regu lations D Fuel loss...

Page 69: ...e not at correct operating tempe rature D Valve clearance not OK D Valves stick D Piston pin or crankshaft bearing loose D Piston ring broken D Let engine warm to operating temperature before running...

Page 70: ...ge D Pinion gear engages but stops turning D Pinion gear conti nues to turn after starter switch is re leased D Pinion gear does not disengage after en gine starts D Battery has insufficient charge D...

Page 71: ...ective Equipment The following protective equipment must be worn S Protective Clothing S Safety Shoes S Safety Gloves 10 2 Safety Instructions Personnel S Decommissioning and recommissioning of the en...

Page 72: ...ks norm can be obtained from our After Sales Service department Nuremberg works NOTE A proper and careful recommissioning of new or operated engines has a great impact on the operating safety and rema...

Page 73: ...he engine at the lower idling speed in order to avoid incorrect lubrication of the cylinder liners 9 Check engine for leaks unusual noises and observe the oil pressure and all temperatures Increase en...

Page 74: ...ustrial diesel engines D2842 LE103 74 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instruct...

Page 75: ...ially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 11 Technical Data 11 1 Dimensions and Weights Specification Value Unit Weight dry D2842 L...

Page 76: ...turbocharger with charge air cooling Number of cylinders 12 Bore 128 mm Stroke 142 mm Displacement 21 930 cm3 Compression ratio 16 5 1 Rating 662 KW 900 PS at 2100 1 min Firing order 1 12 5 8 3 10 6...

Page 77: ...d lubrication Oil capacity in oil sump litres min max 24 l 32 l Oil change quantity with filter 35 l Lubrication oil pressure during operation depending on engine speed oil temperature and engine load...

Page 78: ...rial diesel engines D2842 LE103 78 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instruction...

Page 79: ...LE103 79 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters...

Page 80: ...Industrial diesel engines D2842 LE103 80 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety inst...

Page 81: ...Industrial diesel engines D2842 LE103 81 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety inst...

Page 82: ...Industrial diesel engines D2842 LE103 82 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety inst...

Page 83: ...el engines D2842 LE103 83 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each...

Page 84: ...cm3 Cubic centimetre EDC Electronically controlled diesel injec tion Electronic Diesel Control evtl Possibly Fa Company ggf If necessary GND Ground h Hours Chap Chapter kg Kilogram Tl Terminal kW Kilo...

Page 85: ...ting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 13 2 Technical Terms EDC Electronic Diesel Control is an elect...

Page 86: ...71 Design and Function 27 Dimensions and Weights 75 Disposal 10 E Engine Data 76 Engine Lubrication 27 Engine Model Plate 25 Engine Model Plate Data 38 Engine Monitoring 27 Engine Oil Change 50 Engine...

Page 87: ...el Requirements 15 Preface 7 Preparations before Operation 42 R Recommissioning of Decommissioned Engines 73 Refilling Coolant 43 Refilling Engine Oil 45 Replace oil filter insert 51 Responsibility of...

Page 88: ...el engines D2842 LE103 88 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each...

Page 89: ......

Page 90: ...MAN Truck Bus AG Vogelweiherstra e 33 90441 N rnberg Germany A member of the MAN Group Printed in Germany 51 99493 8579...

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