Man D 0826 LE Operating Instructions Manual
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Man D 0826 LE Operating Instructions Manual

Man D 0826 LE Operating Instructions Manual

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Operating Instructions
Diesel Engine
D 0826 LE
D 0826 LE 201

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Summary of Contents for Man D 0826 LE

  • Page 1 Operating Instructions Diesel Engine D 0826 LE D 0826 LE 201...
  • Page 3 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 re- pair work.

  • Page 4: Table Of Contents

    Index Declaration ............. . . Nameplates .

  • Page 5: Declaration

    In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of Directive 89/392/EEC, version 93/44/EEC MAN Nutzfahrzeuge Aktiengesellschaft, hereby declares that the engine described below is destined for installation in a machine as defined in the EC directive on machines.

  • Page 6: Nameplates

    ..............delivered on ..............installed on ..............Enter 14-digit serial number (is used in the MAN Nutzfahrzeuge Aktiengesellschaft spare parts catalog to distinguish between spare parts). Motor-Nr. / Engine No. NI/II In all your correspondence please always quote engine model, serial number and job number (Order number).

  • Page 7: Safety Regulations

    D Do not touch the engine with bare hands when it is warm from operation – risk of burns. Ë Ë D 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.
  • Page 8 Safety regulations D Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences. During maintenance and care D 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 scald- ing.
  • Page 9 If faults occur, find the cause immediately and have it eliminated in order to prevent more serious damage. Use only genuine MAN spare parts. MAN will accept no responsibility for damage result- ing from the installation of other parts which are supposedly “just as good”.
  • Page 10 Safety regulations 3. Regulations designed to prevent pollution Engine oil and filter elements / cartridges, fuel / fuel filter D Take old oil only to an old oil collection point. D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
  • Page 11 Safety regulations 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, irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances which have caused skin cancer in animal experi- ments.

  • Page 12: Technical Information

    Technical information Engine views D 0826 LE...
  • Page 13 Technical information 1 Fuel filter 2 Starter motor 3 Injection pump 4 Oil filter 5 Oil filler neck 6 Thermostat housing 7 Alternator 8 Oil drain plug 9 Oil dipstick 10 Turbocharger...

  • Page 14: Engines

    Technical information Engines The engine D 0826 LE is in-line vertical liquid-cooled 6-cylinder four-stroke Diesel engine with direct injection, turbocharger and intercooler. Engine block The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is ex- tended to a level below the crankshaft centre line.
  • Page 15 Technical information Engine timing Camshaft, oil pump and injection pump are driven by a gear train arranged at the water pump end via an idler gear from the crankshaft. 1 Crankshaft gear (match-marked with idler gear by “D - D - 1”) 2 Idler gear 3 Camshaft gear (match-marked with idler gear by “2 - 2 - 2”) 4 Injection pump drive gear...

  • Page 16: Engine Lubrication

    Technical information Engine lubrication The engine is equipped with force-feed lubrication. The gear oil pump for the force-feed lubrication system of the engine is fitted on the tim- ing gear case in a recess of the crankcase and driven by gears. 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.
  • Page 17 Technical information The turbocharger and the injection pump are also connected to the engine lubricating system. The cylinder walls and timing gears are splash-lubricated. Each cylinder has an oil jet provided for cooling the underside of the pistons. The lube oil is cleaned in a full-flow oil filter with internal bypass valve. Depending on the agreed extent of delivery and the design of the engine, the lube oil cir- cuit can be equipped with oil pressure monitors (advance warning and cut-off function) which shut the engine down in the event of a sudden loss of pressure.

  • Page 18: Fuel System

    Technical information Fuel system The fuel is delivered by a primary fuel supply pump via the fuel filter to the distributor in- jection pump. The fuel is sprayed into the cylinder through four-hole nozzles fitted in screw-fit injectors in the cylinder heads. Excessive fuel delivered and leak fuel from the injectors flows through the return pipe to the tank.

  • Page 19: Turbocharger

    Technical information Turbocharger The exhaust gases of the engine are passed through the turbine rotor of the turbochar- ger. Air impeller mounted on the same shaft draws in fresh air and delivers it at a higher pressure to the cylinders. The turbocharger is air-cooled.

  • Page 20: Intercooler

    Technical information Intercooler Before entering the cylinders the combustion air compressed in the turbocharger is passed through a heat exchanger (intercooler). Heat removal in the cooler is either by air (air-to-air intercooler) or, in case of the marine application, by means of seawater (air-to-water intercooler) delivered by the raw water pump.

  • Page 21: Electrical Equipment

    Technical information Electrical equipment Alternator The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alternator limits the alternator voltage. The al- ternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator.

  • Page 22: Commissioning And Operation

    “Technical Information down lever to “stop” at the same time for the installation of MAN Diesel en- until the oil pressure warning light goes gines”. out and the oil pressure gauge shows a pressure.

  • Page 23: Starting

    Commissioning and operation Raw water pump Running in Do not let raw water pump run dry. It is recommended that new or overhauled Make sure that all valves / cocks in the engines should not be operated at a load raw water circuit are open.

  • Page 24: Shutting Down

    Temporary anti-corrosion protection ac- even by briefly bringing the connections cording to MAN works norm M 3069 is re- into contact! quired for engines which are to be put out D Do not operate the alternator without of service for fairly long periods.

  • Page 25: Maintenance And Care

    Maintenance and care Engine lubrication Refilling with oil Refill with fresh engine oil at the oil filler neck. Oil level Check the oil level in the engine sump daily with a dipstick. The level should be between the two notches cut into the dip- stick and should never be allowed to drop below the lower notch.

  • Page 26: Fuel System

    Maintenance and care Screw-on type oil filter Fuel system Fuel If Diesel fuel which contains moisture is used the injection system and the cylinder liners / pistons will be damaged. This can be prevented to same extent by filling the tank as soon as the engine is switched off while the fuel tank is still warm (formation of condensation is prevented).
  • Page 27 Maintenance and care Fuel lift pump Parallel fuel filter The fuel lift pump is operated by the injec- The fuel flows through two parallel filters. tion pump camshaft via the roller tappet. Strainer 1 Filter element 2 Vent plugs 1 Fuel strainer 3 Moisture drain plugs 2 Filtering screen 3 Filter housing...
  • Page 28 Maintenance and care Injector maintenance Removal, dismantling and cleaning (by authorized specialist personnel) Unscrew delivery pipe at nozzle holder and at the injection pump. 1 Collar screw 2 Circlip Remove leak-off pipe. 3 Shim 4 Compression spring Release union screw of nozzle holder with 5 Thrust pin special wrench.
  • Page 29 Maintenance and care Before reassembly thoroughly wash Caution: nozzle body and needle in clean test oil. Do not hold your hands under the fuel jet, as there is a risk of injury. Do not Hold the needle at the pintle end only; to inhale the atomised fuel.

  • Page 30: Cooling

    P3-begesol. This cleansing agent is avail- carefully turn the cap (large cap) with able from MAN in 10-kg cans under Part safety valve to the first stop, let off pres- No. 09.21002-0164. sure, then open carefully.
  • Page 31 Maintenance and care Procedure: c) Fill coolant circuit with a mixture of hot D Mix P3-begesol with water, ratio 1:1 water (min. 50°C) and Henkel P 3 neu- D Using a spray gun, spray the mixture in trasel 5265 detergent (1.5% by volume) as straight a jet as possible directly into (-5266, -5225, Kluthe Hakopur 316), the radiator fins...
  • Page 32 Maintenance and care D If necessary, refill the circuit again with Procedure: fresh pickling fluid and pickle the en- D Remove and dismantle the heat ex- gine for another 8 hours changer (integrated in the coolant D Drain the pickling fluid, fill the system surge tank) with tap water, and run the engine at D Place the removed tube bundle in a...
  • Page 33 Maintenance and care Filler caps and working valves of cool- Sources of supply for pickling fluids ing system Lithsolventsäure The rubber gaskets of the filler caps and Keller & Bohacek working valves (negative pressure and Liliencronstr. 54 positive pressure valves) of the cooling D–40472 Düsseldorf system are subject to natural aging.

  • Page 34: Turbocharger

    Maintenance and care Turbocharger Special hints It is recommended that the radial and Maintenance axial clearances of the rotor be checked (by authorized specialist personnel) after every 3000 hours operation. The turbochargers do not call for any spe- This precaution will enable any wear of cific maintenance.
  • Page 35 Axial and radial clearances A = Measuring point for dial gauge Gamme axial radial (mm) (mm) D 0826 LE K 27 0.16 0.43 D 0826 LE 201 K 27 0.16 0.43 If excessive clearances are found, the turbocharger should be replaced.

  • Page 36: Air Cleaner

    Maintenance and care Air cleaner Fouling Indicator As the degree of clogging increases the Dry air cleaner red indicator becomes more and more vis- ible in the transparent section of the air cleaner. If the fouling indicator remains engaged, i.e. it still shows completely red even with the engine shut down, the filter cartridge must be cleaned or replaced.
  • Page 37 Maintenance and care Changing the filter cartridge Blowing out (wear goggles) To do this fit a pipe to the compressed air Caution: gun. The end of the pipe should be bent No dust must get to the clear air end. by approx.
  • Page 38 Maintenance and care Viscous air cleaner On no account re-use damaged car- tridges. If in doubt fit a new cartridge. Safety cartridge The maintenance intervals for filters de- When the main cartridge is being serviced pend on the respective operating condi- the safety cartridge remains in the filter tions.

  • Page 39: Checking And Setting

    Checking and setting To check and set the start of deliv- a. Light signal transmitter 80.99605-6002 (by authorized specialist personnel) Checking Turn engine so that cylinder no. 1 is at the specified number of degrees before firing top dead centre (TDC). Push light signal transmitter into socket in governor housing.
  • Page 40 Checking and setting b. Sleeve ø15 ø12 ø9 Slowly turn the engine further until lamp ø3 (B) comes on too. The injection pump is now at start of delivery. ø11 When the pump is in this position the de- If a light signal transmitter is not available, gree scale on the flywheel housing must good measurement results can also be also indicate the specified start of delivery.
  • Page 41 Checking and setting Setting start of delivery Losen the fixing bolts joining the drive gear to the injection pump hub. For this a If the start of delivery as determined in the full revolution of the engine will be re- checks carried out in accordance with quired.

  • Page 42: To Check And Adjust Valve Clearance

    Checking and setting To check and adjust valve clear- Cylinder head bolts ance General notes (by authorized specialist personnel) The engine may have either of the follow- ing two types of cylinder head bolt: The valve clearance for new and over- hauled engines should be checked after D Cylinder head bolts with the first 10 to 20 hours of operation.
  • Page 43 Checking and setting Retightening cylinder head bolts on new engines (engine cold or warm) by authorized specialist personnel Bolts with hex head tightened by angle-of- rotation method only The cylinder heads are mounted with cyl- inder head bolts which are tightened by the angle-of-rotation method.
  • Page 44 Checking and setting Tightening cylinder head bolts Retightening cylinder head bolts after a repair after repairs (engine cold) (engine cold or warm) by authorized specialist personnel by authorized specialist personnel Bolts with hex head tightened by angle-of- Bolts with hex head tightened by angle-of- rotation method only rotation method only After the first 10 to 20 hours of operation...

  • Page 45: V-Belts

    Checking and setting Tightening cylinder head bolts V-belts after a repair The tension of the V-belts should be (engine cold) checked after every 200 hours of oper- by authorized specialist personnel ation. Bolts with Torx head tightened by angle- of-rotation method only Change the V-belts if necessary Caution: If, in the case of a multiple belt drive, wear...
  • Page 46 Checking and setting Tension and / or replace V-belts D Slowly depress pad  until the spring can be heard to disengage. This will cause the indicator to move upwards Water pump - Alternator If pressure is maintained after the spring D Remove fixing bolts À...
  • Page 47 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 48: Technical Data

    Technical data Model D 0826 LE Design in-line vertical Cycle 4-stroke Diesel with turbocharging / inter- cooling Combustion system Direct injection Turbocharging Turbocharger with intercooling Number of cylinders Bore 108 mm Stroke 120 mm Swept volume 6 596 cm Compression ratio...
  • Page 49 Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. deep, for Generating Sets 16 l 20 l deep, for Marine Propulsion 13 l 16 l standard 10 l 14 l shallow 11 l Oil change quantity (with filter) deep, for Generating Sets 21,5 l deep, for Marine Propulsion...
  • Page 50 Technical data Model D 0826 LE 201 Design in-line vertical Cycle 4-stroke Diesel with turbocharging / inter- cooling Combustion system Direct injection Turbocharging Turbocharger with intercooling Number of cylinders Bore 108 mm Stroke 125 mm Swept volume 6 871 cm...
  • Page 51 Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. deep 16 l 20 l standard 10 l 14 l Oil change quantity (with filter) deep 21,5 l standard 15,5 l Oil pressure during operation (depend- must by monitored by oil pressure moni- ing on oil temperature, oil viscosity tors / gauges...
  • Page 52 Index Air cleaner ......19, 35–37 Nameplates ....... Alternator .
  • Page 54 MAN Nutzfahrzeuge Aktiengesellschaft Vogelweiherstraße 33 D–90441 Nürnberg Printed in Germany 51.99493–8251...

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D 0826 le 201

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