Man marine diesel engine v8 900 (d 2848 le 423) service repair manual

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PrefaceThis Repair Manual is designed to facilitate repair of the engines listed in line with accepted technical principles. In addition to this Repair Manual the…
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PrefaceThis Repair Manual is designed to facilitate repair of the engines listed in line with accepted technical principles. 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 engine 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 Manual. 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 manufacturer’s service department.Best regards MAN Nutzfahrzeuge Aktiengesellschaft Nuremberg PlantWe 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. MTDBTechnical status: 10.2005151.99598−8123InstructionsImportant 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-machineâ€? 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 torqueFitting 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 them2ContentsPage Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes on engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning after engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2848 LE 423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2840 LE 423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2842 LE 423/443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views D 2842 LE 433 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of cooling system D 2842 LE 433 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic diagram of cooling system D 2848/40/42 LE 423/443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 5 6 12 15 16 18 20 22 24 26 29 28 30Fuel system Removing and installing the high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the rail pressure sensor, pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel prefilter with hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the Fuel Service Centre, replacing the filter cartridge . . . . . . . . . . . . . . . . . .31 32 34 37 38 43 44Cooling system Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pipe cluster for heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and repairing pipe cluster for heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning heat exchanger pipe cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing impeller of sea water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sea water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 48 49 51 56 58 60 63 65 66 68Lubrication system Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing, repairing oil pump D 2848 LE 423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing, repairing oil pump D 2840/42 LE 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 70 72 76 81Flywheel / Crankshaft seal Removing and fitting vibration damper, Replacing front crankshaft gasket . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel, Replacing starter gear ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing crankshaft seal (flywheel end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the bearing race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 87 89 90 913ContentsPage Intake / exhaust system Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intake pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger, troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger D 2848/40/42 LE 423/443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger D 2842 LE 433 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring axial / radial clearance of turbocharger shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge pressure control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intercooler D 2848/40/42 LE 423/443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing intercooler D 2842 LE 433 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 93 94 96 98 100 103 104 105 107Cylinder head Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling the rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing valve seat insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reworking valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 113 115 119 125 126 128 131Valve timing Removing and installing the timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 134 137Crankgear, pistons Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pistons with conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing pistons from conrod and fitting, checking − replacing conrod . . . . . . . . . . . . . . . . . . . . . . . Removing and installing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring piston protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 141 144 146 148 152Attachments Removing and installing starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and attaching alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing power take-off for sea water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing power take-off for hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 154 156 160 163Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2124Engine type classificationAll 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: DThe “D” at the start of the type classification stands for “Diesel”28The numbers “28” indicates that the power plant in question has a bore of 128 mm4The “4” means 142 mm stroke8The “8” indicates that there are 8 cylinders. If there is a “0”, this is a 10-cylinder engineLThis letter stands for “charge-air cooling” (German: Ladeluftkühlung)EThe “E” stands for “fitted engine” (German: Einbaumotor) and is intended to distinguish MAN vehicle engines423This is a factory-internal development number5Safety regulationsGeneral notes 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. 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 corrosive 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 accidentally 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 close−fitting working clothesD 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.6ËË ËËSafety regulationsD 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 additional 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 high−precision parts which are exposed to extreme stresses. The high−precision 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 MAN−approved service products (fuel, engine oil, anti−freeze and anti−corrosion 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 op
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