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Faults

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.

Fault

Remedy

Possible cause

Lube-oil pressure too
high

Engine cold

Selected oil viscosity is inappropriate for
ambient temperature (too thick)

Oil pressure indicator faulty

Safety valve in oil circuit faulty (does not
open)

Oil lines/oil ducts clogged

See "Fluids and Lubricants..."

Lube-oil consumption
too high

Lube-oil quality does not meet the regu
lations

Oil level in oil pan too high

Leaks in lube-oil circuit especially at the
turbocharger and oil cooler

Piston rings heavily worn

Valve stems heavily worn, bent

See "Fluids and Lubricants..."

Check whether the guide tube is
correctly installed and the cor
rect oil dipstick is being used

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

Fuel grade does not meet the regu
lations

Fuel loss due to leaks in system

Valve seat leaks

See "Fluids and Lubricants..."

Black smoke accom
panied by loss of power

Air filter clogged

Air intake duct leading to turbocharger
leaks

Exhaust clogged (exhaust back
pressure too high)

Turbocharger faulty

Intercooler leaks, faulty

Injectors faulty, carbonised

Help from the manufacturer ser
vice

Blue smoke

Engine/coolant/intake air still too cold

Lube oil penetrates into combustion
chamber (pistons/piston rings worn or
piston rings broken)

Valve stem/guide worn

Overpressure in crankcase (crankcase
ventilation system clogged)

White smoke

Engine/coolant/intake air still too cold

Fuel tank empty

Air in fuel system

Fuel lines not sealing, broken, blocked

Coolant penetrates into combustion
chamber (cylinder head/gasket leaks)

Fuel filter clogged

Fuel grade does not meet the regu
lations

Injectors faulty

See "Fluids and Lubricants..."

Содержание D2842 LE103

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 89: ......

Страница 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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