MAN D2842 Diesel Engine Operating Instructions Manual

These Operating Instructions are intended to familiarize you with your new MAN Diesel engine and how it operates. This manual is supplemented by the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines” and the “Service record”.

MAN Diesel 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 are observed and only approved fuels, lubricants and coolants are used. It is imperative and in your own interest to entrust your MAN Local Service Centre with the removal of any disturbances and with the performance of checking, setting, and repair work.

General notes
Handling diesel engines and the necessary resources is no problem when the personnel commissioned with operation and maintenance are trained accordingly and use their common sense.

This summary is a compilation of the most important regulations. These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution. In addition to these regulations those dictated by the type of engine and its site are to be observed also.

During commissioning, starting and operation

1. 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.
2. For reasons of safety we recommend you attach a notice to the door of the engine room prohibiting the access of unauthorized persons and that you draw the attention of the operating personal to the fact that they are responsible for the safety of persons who enter the engine room.
3. The engine must be started and operated only by authorized personnel. Ensure that the engine cannot be started by unauthorized persons.
4. When the engine is running, do not get too close to the rotating parts. Wear close fitting clothing.
5. Do not touch the engine with bare hands when it is warm from operation – risk of burns.
6. Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.
7. Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences.

During maintenance and care

1. Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts.
2. Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the oil will not overflow.
3. 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 the chapter entitled “Maintenance and Care”.
4. 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.
5. Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only when the engine is switched off.

Piston / Conrod / Crank assembly
The forged crankshaft has screwed-on counterweights. Radial seals with replaceable wearing rings on crankshaft and flywheel are provided to seal the crankcase penetrations. The connecting rods are die-forged, diagonally split and can be removed through the top of the cylinders together with the pistons. Crankshaft and connecting rods run in steel backed lead bronze ready-to-fit type bearings.

Engine lubrication
The engine is equipped with force-feed lubrication. The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the flywheel end. The oil pump draws the oil 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 small-end bearings and the rocker arms.

Injection pump
The in-line injection pump is driven via gears from the crankshaft. It is connected to the force-feed lubricating system of the engine and consequently maintenance-free. The centrifugal governor flange-mounted on the pump casing is a variable range governor designed to keep the speed set by the control lever constant under conditions of varying load. The governor of the turbocharged engines has a full load stop controlled by the charge air pressure and is designed to decrease the full load fuel quantity in the low speed range from a certain (adjustable) charge-air pressure onwards.