<p>Preface 1 This Repair Manual is designed to facilitate repair of the engines listed in line with accepted technical prin- ciples. In addition to this Repair Manual the following publications are available: D Operating Instructions D Fuels, Lubricants and Coolants for MAN Diesel Engines D Spare-parts catalogue D Service record book with maintenance plan Note: Only use fuel, coolants and lubricants in accordance with MAN's 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 in the internet under: http://www.mn.man.de/index/mn_eng/motor/serviceproducts.htm The pictures and associated descriptions show typical work that may not always be applicable to the en- gine 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 describe in this Repair Man- ual. The expert knowledge necessary for handling Diesel engines was taken for granted when this publication was compiled. Any repair of components such as injection pump, alternator etc. ought to be left to our or the manufac- turer's service department. Best regards MAN Nutzfahrzeuge Aktiengesellschaft Nuremberg Plant We reserve the right to make technical modifications in the course of further development. 2005 MAN Nutzfahrzeuge Aktiengesellschaft Reprinting, duplication or translation, in whole or in part, is not permitted without the written permission of MAN. MAN reserves all rights accorded by the relevant laws on copyright. MTDB Technical status: 10.2005 51.995988123 Instructions 2 Important instructions which concern technical safety and protection of persons are emphasised as shown below. 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 Flat seals / gaskets are often inserted with sealing agents or adhesives to make fitting them easier or to achieve better sealing. Flat seals may slip in operation due to the "sewing-machine" effect, in particular if they are used between parts with different rates of linear expansion under heat (e.g. aluminium and cast iron), and leaks may then 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. Flat seals / gaskets can be fitted properly only if the following points are observed: 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 Fitting 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 Contents 3 Page Preface 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type classification 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault table 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes on engine overhaul 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning after engine overhaul 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2848 LE 423 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2840 LE 423 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2842 LE 423/443 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2842 LE 433 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine lubrication schedule 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of cooling system D 2842 LE 433 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of cooling system D 2848/40/42 LE 423/443 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel diagram 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system Removing and installing the high-pressure lines 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing high-pressure pump 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the rail 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the rail pressure sensor, pressure relief valve 37 . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the injectors 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel prefilter with hand pump 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the Fuel Service Centre, replacing the filter cartridge 44 . . . . . . . . . . . . . . . . . . Cooling system Draining and filling coolant 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostats 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing coolant pump 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning cooling system 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heat exchanger 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pipe cluster for heat exchanger 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and repairing pipe cluster for heat exchanger 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning heat exchanger pipe cluster 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing impeller of sea water pump 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sea water pump 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication system Changing oil filter 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the oil cooler 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing, repairing oil pump D 2848 LE 423 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing, repairing oil pump D 2840/42 LE 4.. 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil injection nozzle 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel / Crankshaft seal Removing and fitting vibration damper, Replacing front crankshaft gasket 83 . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel, Replacing starter gear ring 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing crankshaft seal (flywheel end) 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the bearing race 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft seals 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents 4 Page Intake / exhaust system Removing and installing air filter 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intake pipes 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing exhaust pipe 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger, troubleshooting 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger D 2848/40/42 LE 423/443 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger D 2842 LE 433 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring axial / radial clearance of turbocharger shaft 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge pressure control valves 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intercooler D 2848/40/42 LE 423/443 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intercooler D 2842 LE 433 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head Removing and installing cylinder head 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the valve clearance 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling the rocker arm mechanism 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valves 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valve guides 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing valve seat insert 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reworking valve seat 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refacing valves 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve timing Removing and installing the timing case 132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the valve timing 137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankgear, pistons Removing and installing crankshaft 138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pistons with conrods 141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing pistons from conrod and fitting, checking replacing conrod 144 . . . . . . . . . . . . . . . . . . . . . . . Removing and installing piston rings 146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing cylinder liners 148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring piston protrusion 152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachments Removing and installing starter motor 153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and attaching alternator 154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-belts 156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing power take-off for sea water pump 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing power take-off for hydraulic pump 163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Data 165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type classification 5 All the engines dealt with here are related in terms of their design and make up a family. The type classification, which is made up of a series of letters and numbers, reveals some of the features of the engine in question provided the reader is familiar with the underlying nomenclature. The system is explained below using the model type D 2848 LE 423 as an example: D The "D" at the start of the type classification stands for "Diesel" 28 The numbers "28" indicates that the power plant in question has a bore of 128 mm 4 The "4" means 142 mm stroke 8 The "8" indicates that there are 8 cylinders. If there is a "0", this is a 10-cylinder engine L This letter stands for "charge-air cooling" (German: Ladeluftkhlung) E The "E" stands for "fitted engine" (German: Einbaumotor) and is intended to distinguish MAN vehicle engines 423 This is a factory-internal development number Safety regulations 6 General notes This summary is a compilation of the most important regulations. These are broken down into main sec- tions which contain the information necessary for preventing injury to persons, damage to property and pollution. 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 During installation work, switch off the battery master switch. D When carrying out maintenance and repair work, ensure that the engine cannot be ac- cidentally started from the bridge by unauthorised persons. D The engine must be started and operated only by authorized personnel. D When the engine is running, do not get too close to the rotating parts. Wear closefitting working clothes D Do not touch hot engine with bare hands: Risk of burns. D Keep area surrounding engine, ladders and stairways 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 stand under an engine suspended on a crane hook. Keep lifting gear in order. D Open the coolant circuit only 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 tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional hydraulic oil circuit) during the operation. The fluids which flow out can cause injury. Safety regulations 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 Comply with the manufacturer's instructions when handling batteries. Caution: Accumulator 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 addi- tional 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 Today modern components of diesel injection consist of highprecision parts which are exposed to ex- treme stresses. The highprecision technology requires the utmost cleanliness during all work on the fuel system. Even a particle of dirt over 0.2 mm can lead to the failure of components. D Use only MANapproved service products (fuel, engine oil, antifreeze and anticorrosion agent). Pay attention to cleanliness. Diesel fuel must be free of water. D Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine may result if these instructions are not adhered to. 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 Oper- ator's Manual. Safety regulations 8 3. Regulations designed to prevent pollution Engine oil and filter elements / cartridges, fuel / fuel filter D Hand old oil over to old oil disposal companies only. D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground. Caution: Risk of contamination of potable water. D Filter elements are classed as dangerous waste and must be treated as such. Coolants D Treat undiluted anticorrosion agent and / or antifreeze as dangerous waste. D The regulations of the respective local authorities must be observed when used coolant is disposed of. 4.Notes on safety in handling used engine oil Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, ir- ritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous sub- stances which have caused skin cancer in animal experiments. If the basic rules of hygiene and health and safety at work are observed, health risks are not to the expected as a result of handling used engine oil. Health precautions: D Avoid prolonged or repeated skin contact with used engine oil. D Protect your skin by means of suitable agents (creams etc.) 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 hands. Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents. D After washing apply a fatty skin cream to the skin. D Change oil-soaked clothing and shoes. D Do not put oily rags into your pockets. Ensure that used engine oil is disposed of in the appropriate manner. Engine oil can endanger the water supply For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are punishable. Collect and dispose of used engine oil carefully. For information on collection points please contact the seller, the supplier or the local authorities. Based on "Information sheet for handling used engine oil". Safety regulations 9 5. Special instructions when working on the common rail system Accident protection D Risk of injury! Fuel jets can cut through skin. The atomisation of fuel creates a fire risk. When the engine is running never loosen the screw connections on the fuel's high- pressure side of the common rail system (injection line from the high-pressure pump to the rail, on the rail and on the cylinder head to the injector) Keep away from the engine when it is running D Risk of injury! When the engine is running the lines are constantly under a fuel pressure of up to 1600 bar. Wait at least a minute until the pressure in the rail has dropped before loosening a screw connection If necessary check the pressure drop in the rail with MAN-Cats D Risk of injury! People with pacemaker must keep at least 20 cm away from the running engine Do not touch live parts on the electric connection of the injectors when the engine is running Safety regulations 10 Cleanliness Today modern components of diesel injection consist of high-precision parts which are exposed to extreme stresses. The high-precision technology requires the utmost cleanliness during all work on the fuel sys- tem. Even a particle of dirt over 0.2 mm can lead to the failure of components. The measures described as follows are therefore essential before work begins: Risk of damage from penetration of dirt! D Before working on the clean side of the fuel system clean the engine and the engine compartment (high-pressure cleaner). During cleaning the fuel system must be closed D Carry out visual inspection for any leakage or damage to the fuel system D Do not spray the high-pressure cleaner direct onto the electric components, or alternati- vely keep them covered D Do not carry out any welding or sanding work in the engine compartment during mainte- nance / repair D Avoid air movements (any swirling of dust when starting engines) D The area of the still closed fuel system must be cleaned and dried with the aid of com- pressed air D Remove detached particles of dirt such as paint chippings and insulation material with a suitable extractor (industrial type vacuum cleaner) D Cover areas of the engine compartment from which dust particles could be detached with clean foil D Wash your hands and put on clean work clothes before starting the disassembly work D Clean tools and working materials before starting to work Safety regulations 11 When carrying out the work it is essential to comply with the following measures: Risk of damage from penetration of dirt! D When the clean side of the fuel system has been opened it is not permissible to use compressed air for cleaning D During assembly work loose dirt must be removed with the aid of suitable extractors (industrial type vacuum cleaners) D Use only fluff-free cleaning cloths on the fuel system D Only tools without any damage may be used (cracked chrome coatings) D When removing and installing components do not use materials such as cloths, cardbo- ard or wood since these could shed particles and fine fibres D If any paint chips / flakes off when connections are loosened (from possible over-coa- ting) these chippings must be carefully removed before finally loosening the screw con- nection D The connection openings of all removed parts on the clean side of the fuel system are to be closed immediately with suitable caps (see special tools, page 208) D These caps / stoppers must be packed protected from dust prior to use and after being used once they must be disposed of D Following this all the components must be carefully stored in a clean, closed container D Never use used cleaning or testing liquids for these components D New parts must not be removed from their original packing material until directly before use D Work on removed components may be carried out only at a workplace specially equip- ped for it D If removed parts are shipped always use the original packing material of the new part Fault table 12 Operating faults and possible causes We recommend A repair is only complete when both the damage that occurred and the possible causes have been elimin- ated. Finding out the cause of damage is often more difficult than repairing the damage that occurred. We therefore recommend that you obtain a precise description of the operating fault before "removing and dis- mantling" components. Then use a process of elimination (questions) to pinpoint the probable causes and investigate and eliminate these successively on the basis of the table and your own experience. This helps to reduce repairs to the required scale and to counteract claims regarding "over-eager" replacement of parts and complaints about expensive work and down time. Note: The following list is conceived as an aid to memory for experts so that to causes of damage are overlooked when dealing with faults. The precondition for this, however, is that the experts are familiar with the Repair Manual for the engine as well as the accompanying Operating Instructions and the publication "Fuels, Lubricants and Coolants for MAN Diesel Engines". Fault table 13 x = Probable o = Possible 1. EDC self-diagnosis or flash code output 2. Starter motor turns over engine slowly or not at all 3. Starter motor turns, engine fails to start, engine fails to start / difficult to start when cold 4. Engine stalls (dies) during operation, no longer starts (starter motor turns), engine fails to start / difficult to start when hot 5. Sudden, temporary engine shutdown, engine does not reach full revs 6. Engine runs at idle speed only, no throttle response 7. Engine runs at increased idle speed only, no throttle response 8. Rated engine speed significantly reduced (even at no load) 9. Reduced power output in all ranges 10. Irregular engine operation, loss of traction 11. Unstable idle speed, engine surges, misfiring, engine knocking 12. Engine judder 13. Unusual combustion noises 14. Excessive smoke emission: white smoke / blue smoke 15. Excessive smoke emission: black smoke 16. Engine temperature too high (coolant loss) 17. Fuel consumption too high 18. Lubrication oil pressure too low 19. Lube oil pressure too high 20. Lube oil consumption too high 21. Engine too "loud" / mechanical noises 22. Idle speed cannot be adjusted with idle speed operating unit Possible causes x x Battery flat, battery lead connections loose or corroded, break in power circuit x Crankshaft drive blocked x x Starter solenoid switch sticks (clicks) / damaged, cable connection loose or dam- aged x x Starter motor / starter interlock relay defective (carbon brushes worked loose / worn, winding damaged, short to ground) x x x x Engine oil viscosity unsuitable, not suitable for ambient temperature, lube oil qual- ity does not comply with specifications x x Oil level in oil pan too high x Oil level in pan too low, oil in oil pan too thin (mixed with condensate or fuel) x Engine temperature too high x Oil filter clogged x x Oil pressure gauge defective x Safety valve in the oil circuit defective (does not close, spring fatigued or broken) x x Heavy bearing wear x Oil pump gears heavily worn x Timing gears worn, tooth flank backlash too great x x x Engine cold x Lube oil entering combustion chamber (piston rings worn, piston rings broken) valve stem guide worn overpressure in crankcase (crankcase breather clogged) x Safety valve in oil circuit defective (does not open), oil lines / oil galleries clogged x Leaks in lube oil circuit, particularly at turbocharger and oil cooler x x Piston rings heavily worn, broken x x Piston pins or crankshaft bearings loose x Valve stems heavily worn, bent x x x Valve clearance not correct x x Valves jammed x x x x Compression deficient, or more than 34 bar pressure difference between individ- ual cylinders x x x Valve seats leaking o x x Increased power input due to defective secondary loads / consumers such as hydraulic pumps, fan etc., power take-off engaged x x x x x Air filter fouled or clogged, charge air system leaking, air intake / exhaust lines clogged / leaking x x x x x x x x x Fuel low pressure system: fuel tank, prefilter, water trap faulty / clogged / mould / fungal attack, fuel unsuitable / contaminated (paraffin added) x x x x x x x x Fuel low pressure system: fuel lines leaking, broken, clogged Fault table 14 x = Probable o = Possible 1. EDC self-diagnosis or flash code output 2. Starter motor turns over engine slowly or not at all 3. Starter motor turns, engine fails to start, engine fails to start / difficult to start when cold 4. Engine stalls (dies) during operation, no longer starts (starter motor turns), engine fails to start / difficult to start when hot 5. Sudden, temporary engine shutdown, engine does not reach full revs 6. Engine runs at idle speed only, no throttle response 7. Engine runs at increased idle speed only, no throttle response 8. Rated engine speed significantly reduced (even at no load) 9. Reduced power output in all ranges 10. Irregular engine operation, loss of traction 11. Unstable idle speed, engine surges, misfiring, engine knocking 12. Engine judder 13. Unusual combustion noises 14. Excessive smoke emission: white smoke / blue smoke 15. Excessive smoke emission: black smoke 16. Engine temperature too high (coolant loss) 17. Fuel consumption too high 18. Lubrication oil pressure too low 19. Lube oil pressure too high 20. Lube oil consumption too high 21. Engine too "loud" / mechanical noises 22. Idle speed cannot be adjusted with idle speed operating unit Possible causes x x x x x x x Fuel low pressure system: air in system (turn on ignition when bleeding system) x x x x x x x x x Fuel low pressure system: feed pump, main filter x x x x x o x x Fuel high pressure system: injectors defective / clogged / leaking / coked x x x x o Fuel high pressure system: pressure lines constriction, cavitation, leaking x x o x x x x o Fuel high pressure system: high-pressure pump worn x x x x x o Pedal value sensor (driving lever signal) defective: connection lines, short circuit, interruption x x EDC rpm sensor defective, lead defective x x o EDC rpm sensor, polarity reversed x x x x o o o o EDC detects incorrect engine speed (interference signal on rpm sensor lead) x x x EDC boost pressure sensor: faulty, incorrect, implausible with atmospheric pres- sure sensor, line fault x x o x Exhaust turbocharger leaking or defective x Turbine and compressor wheel in the turbocharger soiled (running off balance) x Intercooler leaking, defective x o x x o x EDC coolant temperature sensor: faulty, line fault x x x EDC charge-air temperature sensor: faulty, line fault o x x Radiator fouled or failure of cooling system (temperatures too high) x Coolant level too low, air in the coolant circuit x V-belt for coolant pump drive not tensioned correctly x x Incorrect V-belt tension x Coolant pump leaking, defective / thermostat defective, does not open x Coolant lines leaking, blocked or twisted x Coolant entering combustion chamber (cylinder head / gasket leaking) x x x o o Power supply to EDC control unit interrupted or battery voltage too low x o o o EDC control unit defective (internal fault) x x x x o o o x Incorrect EDC control unit (check MAN part number) x Afterrunning not completed x x Thermostat defective x Engine bearings worn General notes on engine overhaul 15 The service life of an engine is influenced by very different factors. It is therefore not possible to specify certain fixed numbers of operating hours for general overhauls. In our view, it is not necessary to open up and engine or perform a general overhaul as long as the engine has good compression values and the following operating values have not changed significantly in relation to the values measured on commissioning the engine: D Charging pressure D Exhaust temperature D Coolant and lubricant temperature D Oil pressure and oil consumption D Smoke emissions The following criteria greatly influence the length of the engine service life: D Correct power output setting according to the type of application D Technically correct installation D Inspection if installation by authorised personnel D Regular maintenance as per maintenance plan D Choice and quality of lube oil, fuel and coolant in accordance with the publication "Fuels, Lubricants and Coolants for MAN Diesel Engines" Commissioning after engine overhaul 16 Pressurisation It is extremely important for internal combustion engines (following the completion of repair work, i.e. in their dry state) to be pressurised with lube oil before being recommissioned. This procedure can also be used for ascertaining damage and its causes. If engines are not pressurised, the risk of premature damage to bearing surfaces is very high because it takes a relatively long period of time for the lube oil drawn in from the oil pan via the oil pump to reach the individual bearings. Such incipient damage need not necessarily lead to immediate bearing failure, but may impair the proper functioning of the bearings and reduce their service lives. Diagram of the oil flow with unpressurised engines Commissioning after engine overhaul 17 Pressurising an engine affords the following advantages: D All engine parts are lubricated before engine startup; a lubricating film can be built up inside the bear- ings as early as after the first few rotations of the crankshaft, thereby preventing damage to the bearing races D Any loss of oil, be it the result of excessively large bearing play or leaks from the crankcase or from crankcase bores which may not be plugged, can be detected immediately. For this purpose, mount the engine on an assembly dolly, remove the oil pan and install a suitable oil collector under the crankcase in such a way that the bearings are visible Performance of pressurisation: At least 30% of the total oil quantity is forced from the pressurisation container into the engine oil circuit. The operating pressure serves as the yardstick for the pressure to be forced in and must not be exceeded. The pressurisation container is connected up to the engine oil circuit at the oil filter (screw plug). Engine views 18 Engine views D 2848 LE 423 2 3 6 5 1 9 12 5 4 7 10 11 9 13 8 1 14 15 16 18 19 20 14 17 Engine views 19 Airfilter Relief valve on coolant surge tank Intercooler Heat exchanger and coolant surge tank Tensioning pulley Alternator Engine cranking device Coolant filler neck Oil drain plugs Coolant pump 11 Oil sump 12 Oil cooler 13 Oil filter 14 Turbocharger 15 Exhaust manifold 16 Fuel Service Center 17 Crankcase breather 18 Oil filler neck 19 Sea water pump 20 Fuse box Engine views 20 Engine views D 2840 LE 423 2 4 3 6 1 11 5 8 9 10 12 13 7 14 15 16 17 15 19 12 18 Engine views 21 Airfilter Relief valve on coolant surge tank Intercooler Heat exchanger and coolant surge tank Alternator Engine cranking device Tensioning pulley Coolant filler neck Coolant pump Oil sump 11 Oil cooler 12 Oil drain plugs 13 Oil filter 14 Exhaust manifold 15 Turbocharger 16 Fuel Service Center 17 Crankcase breather 18 Sea water pump 19 Fuse box Engine views 22 Engine views D 2842 LE 423/443 6 7 1 2 3 4 5 8 9 10 11 12 13 5 15 16 17 18 14 Engine views 23 Airfilter Intercooler Relief valve on coolant surge tank Heat exchanger and coolant surge tank Tensioning pulley Alternator Engine cranking device Coolant pump Coolant filler neck Oil pan 11 Oil cooler 12 Oil drain plugs 13 Oil filter 14 Oil filler neckTurbocharger 15 Crankcase breather valve 16 Turbocharger 17 Sea water pump 18 Fuse box Engine views 24 Engine views D 2842 LE 433 2 3 6 5 1 9 5 4 7 10 11 9 13 14 8 12 16 15 19 20 17 18 Engine views 25 Intercooler stage 1 Intercooler stage 2 Relief valve on coolant surge tank Heat exchanger and coolant surge tank Tensioning pulley Alternator Engine cranking device Coolant filler neck Oil drain plugs Oil pan 11 Oil cooler 12 Oil filter 13 Fuel Service Center 14 Turbocharger 15 Oil dipstick 16 Exhaust manifold 17 Air filterSea water pump 18 Fuel pump 19 Sea water pump 20 Fuse box Engine lubrication schedule 26 1 2 3 4 5 6 7 7 8 9 5 Oil line to crankshaft High-pressure pump lubrication Lubricating oil lines to exhaust turbochargers Oil return line from exhaust turbochargers Holes for main bearing lubrication Oil pump with oil pressure relief valves Holes for conrod bearing lubrication Oil drain screw Oil intake pipe Engine lubrication schedule 27 1 1 2 3 4 5 6 7 8 9 10 11 Lubricating oil lines to exhaust turbochargers Rocker arm lubrication Piston pin lubrication Spray nozzles for piston cooling and cam lubrication Camshaft bearing lubrication Oil intake pipe Oil pressure relief valves Oil cooler Bypass valve Oil filter 11 Main oil galleries Schematic diagram of cooling system D 2842 LE 433 28 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Sea water inlet Sea water pump Exhaust turbocharger, liquid-cooled Exhaust manifold, liquid-cooled Exhaust pipe, liquid-cooled Intercooler Coolant temperature measuring point Coolant line with throttle Expansion tank Positive pressure / negative pressure valve 11 Coolant filler neck 12 Heat exchanger, engine coolant / sea water 13 Sea water outlet 14 Thermostat 15 Heater feed and return system 16 Coolant pump 17 Crankcase 18 Engine oil cooler 19 Gearbox oil cooler Thank you very much for your reading. 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