MAN D2840, D2842, D2848 Operating Instruction
Operating Instructions
MAN Industrial Diesel Engines
D2848 LE201/203/211/213
D2840 LE201/203/211/213
D2842 LE201/203/211/213
51.99493-8509 “Translation of the original operating instructions”
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Information and Copyright
Subject 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 copyright law are strictly reserved by MAN.
© 2011
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1930
Email: engines.components@de.man-mn.com
Internet: www.man-engines.com
Editorial: EMDGG, 01.2011
51.99493-8509
Carefully read the Operating Instructions before starting any work!
2
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Table of Contents
Information and Copyright 2...............................................................
1 Preface 7...........................................................................
1.1 Information about Operating Instructions 7.........................................
1.1.1 Publications belonging to the Operating Instructions 7..........................
1.1.2 Additional Publications for the Engines 7......................................
1.2 Key to Symbols 8...............................................................
1.3 Limitation of Liability 9...........................................................
1.4 Copyright 9....................................................................
1.5 Other 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 Modifications and Conversions to the Engine 14.....................................
2.4 Responsibility of the Operator 14...................................................
2.5 Personnel Requirements 15.......................................................
2.5.1 Qualifications 15............................................................
2.5.2 Unauthorised Persons 15....................................................
2.5.3 Instructions 15.............................................................
2.6 Personal Protective Equipment 16.................................................
2.7 Specific Dangers 17..............................................................
2.8 Safety Equipment 20.............................................................
2.9 Conduct in Dangerous Situations and When Accidents Occur 21.......................
2.10 Signs 22........................................................................
2.11 Environmental Protection 23.......................................................
3 Engine Model Plate 25................................................................
3.1 Explanation of the Motor-Nr./Engine-No. (Engine Identification Number) 26..............
3.2 Explanation of Model Designation 26...............................................
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.
3
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Table of Contents
4 Design and Function 27..............................................................
4.1 Engine, General 27..............................................................
4.2 Engine Views 28.................................................................
4.2.1 Front Left View 28..........................................................
4.2.2 Rear Right 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 Packaging 36....................................................................
5.6 Storage 36......................................................................
6 Installation and Commissioning 37....................................................
6.1 Prerequisite 37..................................................................
6.2 Safety Instructions 37............................................................
6.3 Installation - Engine 38...........................................................
6.3.1 Safety Equipment 38........................................................
6.3.2 Engine Model Plate Data 38.................................................
6.4 Commissioning 39...............................................................
6.4.1 Filling Diesel Fuel 39........................................................
6.4.2 Filling Coolant 40...........................................................
6.4.3 Filling Engine Oil 41.........................................................
Carefully read the Operating Instructions before starting any work!
4
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Table of Contents
7 Operation 43.........................................................................
7.1 Prerequisite 43..................................................................
7.2 Safety Instructions 43............................................................
7.3 Preparations before Operation 44..................................................
7.3.1 Checking and Refilling Fuel Supply 44.........................................
7.3.2 Checking Coolant 45........................................................
7.3.3 Refilling Coolant 46.........................................................
7.3.4 Checking Engine Oil Level 47................................................
7.3.5 Refilling Engine Oil 48.......................................................
7.4 Operation 49....................................................................
7.4.1 Monitoring Operation 49.....................................................
7.4.2 Stopping in an Emergency 49................................................
8 Maintenance and Care 51.............................................................
8.1 Prerequisite 51..................................................................
8.2 Safety Instructions 51............................................................
8.3 Maintenance Schedule 52.........................................................
8.4 Maintenance Work 53............................................................
8.4.1 Engine Oil Change 53.......................................................
8.4.2 Cleaning Fuel Prefilter 61....................................................
8.4.4 Changing Fuel Filter 62......................................................
8.4.7 Bleeding the Fuel System 64.................................................
8.4.8 Changing Coolant 65........................................................
8.4.9 Changing V-Belt 68.........................................................
9 Faults 71............................................................................
9.1 Prerequisite 71..................................................................
9.2 Safety Instructions 71............................................................
9.3 Fault Table 72...................................................................
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.
5
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Table of Contents
10 Decommissioning and Recommissioning 77...........................................
10.1 Prerequisite 77..................................................................
10.2 Safety Instructions 77............................................................
10.3 Temporary Decommissioning of Engines 78.........................................
10.4 Recommissioning of Decommissioned Engines 79...................................
10.4.1 Commissioning of Preserved Engines according to MAN-Werknorm M 3059 79.....
10.4.2 Commissioning of Non-Preserved Engines 79..................................
11 Technical Data 81....................................................................
11.1 Dimensions and Weights 81.......................................................
11.1.1 D2848 LE201/203/211/213 81................................................
11.1.2 D2840 LE201/203/211/213 81................................................
11.1.3 D2842 LE201/203/211/213 81................................................
11.2 Installation Location and Space Requirements 81....................................
11.3 Engine Data 82..................................................................
11.3.1 D2848 LE201/203/211/213 82................................................
11.3.2 D2840 LE201/203/211/213 84................................................
11.3.2 D2842 LE201/203/211/213 86................................................
12 Declaration of incorporation 89........................................................
13 Indices 93..............................................................................
13.1 Abbreviations 94.................................................................
13.2 Technical Terms 95..............................................................
13.3 Index 96........................................................................
14 Notes 98.............................................................................
Carefully read the Operating Instructions before starting any work!
6
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Foreword
1 Preface
1.1 Information about Operating Instructions
These Operating Instructions provide important information on dealing with engines. Prerequisite for safe
operation is the compliance with all safety and handling instructions.
Furthermore, the local accident prevention regulations valid for the engine's area of application and the
general safety regulations must be observed.
Timely and proper maintenance and care of the engines according to the set maintenance intervals ensure
and maintain the operational safety and the reliable application of these engines.
Use only genuine MAN spare parts and accessories or those approved by MAN.
Only MAN approved genuine spare parts have been tested by us and thus suitable for use in our engines.
A particular concern of MAN is to improve 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 the highest requirements.
Economical operation helps to conserve our resources and our environment.
1.1.1 Publications belonging to the Operating Instructions
The following publications belong to the Operating Instructions
- Fluids and Lubricants for MAN Diesel Engines
- Maintenance Record
- Assembly Instructions
All publications are considered "parts of the product" and should always be kept in the immediate vicinity of
the engine for the personnel.
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.
Failure to observe these Operating Instructions and any accompanying supplier operating instructions
leads to the loss of warranty claims.
1.1.2 Additional Publications for the Engines
The following instructions supplement the Operating Instructions for the engines:
For the operator, maintenance and service personnel
- Spare Parts Catalogue (included)
For the service personnel
- Repair Instructions
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.
7
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Foreword
1.2 Key to Symbols
Warnings
Warnings are identified in these Operating Instructions with symbols. These warnings are pre
ceded by signal words that express the magnitude of the risk.
Always heed these warnings and act prudently to prevent accidents, injuries and property damage.
DANGER!
... indicates an imminently 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!
... indicates a possible hazardous situation, which can lead to minor or light injuries if not
avoided.
IMPORTANT!
indicates a possible dangerous situation that can lead to property damage if it is not
avoided.
Tips and Recommendations
NOTE!
highlights useful tips and recommendations as well as information for efficient and smooth
operation.
General Information
• This symbol indicates a list at the first level.
- This symbol indicates a list at the second level.
1. This symbol indicates a sequence of actions.
(1) In the text, this symbol indicates a position in a graphic.
Carefully read the Operating Instructions before starting any work!
8
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Foreword
1.3 Limitation of Liability
All of the information in these instructions have been prepared while taking into account the valid standards
and regulations, the state of the art, as well as our many years of experience and knowledge.
MAN is not liable for damages resulting from:
S Failure to follow these instructions
S Improper use
S Use of untrained personnel
S Customer conversions
S Technical modifications
S Use of non-approved spare parts and fluids and lubricants
The actual scope of delivery for special versions, additional ordering options or technical modifications 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 applicable at the time of contracting arrangements.
1.4 Copyright
Please handle these Operating Instructions as confidential. They are only to be used by the persons work
ing with the engine. Transfer to a third party without explicit written permission from MAN is strictly prohib
ited.
NOTE!
The information, texts, drawings, illustrations and other depictions are all protected by copy
right and are subject to industrial property rights. Any improper use is punishable by law.
1.5 Other Applicable Documents
Supplier components are installed in the engine (e.g. injection system). Risk assessments have been car
ried out on these parts by the suppliers.
The compliance of construction with the existing European and national legislation has been declared by
the respective suppliers of the components.
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.
9
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Foreword
1.6 Spare Parts
Use only genuine MAN spare parts and accessories or those approved by MAN.
Only MAN approved genuine spare parts have been tested by us and thus suitable for use in our engines.
Spare parts and accessories must either be MAN genuine parts or parts that have been specifically ap
proved by MAN. The reliability, safety and suitability of these parts have been established specifically for
the engines. We cannot assess and vouch for other non-MAN products, despite ongoing market observa
tions.
WARNING!
Risk of injury from incorrect spare parts!
Incorrect or faulty spare parts can lead to damage, malfunctions or total failures and inter
fere with safety.
For this reason:
S Only use MAN genuine parts
NOTE!
Please always specify the engine model, engine number and order number when corres
ponding with MAN, see page 25.
Order spare parts through an authorised dealer or directly from MAN.
For addresses, see page 2.
1.7 Disposal
Dispose in accordance with national regulations.
If no return or disposal agreement has been made, recycle the disassembled components as follows:
S Sort metals before scrapping
S Recycle plastic parts
S Dispose of all other parts according to their material composition
10
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.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Foreword
1.8 Warranty Terms
Valid are the commitments agreed upon in the delivery contract and the General Terms and Conditions of
MAN and the law applicable at the time of contracting arrangements.
Failure to observe these Operating Instructions and any accompanying supplier operating instructions
leads to the loss of warranty claims.
The use of non-approved parts leads to the loss of warranty claims.
We recommend to use genuine parts even after the warranty period has passed. This will ensure the con
tinuous performance of the engine.
1.9 Service
Our MAN product support is available for technical information.
NOTE!
Please always specify the engine model, engine number and order number when corres
ponding with MAN, see page 25.
Information about contact persons can always be called up by telephone, fax, email or over the Internet.
For addresses see page 2.
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.
11
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Foreword
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 in each of the chapters.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2 General Safety Instructions
This chapter provides information on residual risks and hazards during proper use of the engine. The gen
erally valid safety instructions to be observed are listed here. They provide optimum protection for person
nel and for the safe and smooth operation of the engine.
In the following, specific, action and situation-related safety information is placed before the corresponding
step, or in the chapter described.
Failure to observe the Operating Instructions and Safety Instructions in this document can result in signific
ant hazards.
2.1 Intended Use
This engine is built solely to drive power generators on land.
Any other use is considered as "not intended".
MAN is not liable for any damage resulting from use that is not intended. The risk is entirely borne by the
operator.
Intended 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 informed of the hazards.
Unauthorised modifications to the engine shall void any liability for any resulting property damage and per
sonal injury.
Likewise, the manipulation of the injection and control system could affect the performance and emission
characteristics of the engine. Compliance with the statutory environmental requirements can therefore no
longer be guaranteed.
DANGER!
Danger from not using the product as intended!
Any use that exceeds the intended use and/or any different use of the engine can lead to
dangerous situations which will invalidate the operating permit.
For this reason:
S Use the engine for its intended purpose only.
S Use the engine outside of hazardous areas where there is a risk of explosion.
S Use the engine with an overspeed limiting device installed.
NOTE!
Observe the following information when operating the engine:
S The safety information in these Operating Instructions and in the supplier's operating in
structions.
S The “Technical Data" chapter in these Operating Instructions and in the supplier's operat
ing instructions.
S Country-specific regulations.
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.
13
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.2 Contents of the Operating Instructions
Any person who is instructed to perform work on or with the engine, must have read and understood these
Operating Instructions before starting any work. This also applies if the person has worked with such an
engine or a similar engine, or has already been trained by MAN.
Reading and understanding the Operating Instructions is thus mandatory.
2.3 Modifications and Conversions to the Engine
In order to avoid hazards and to ensure optimum performance, no modifications or conversions to the en
gine may be made which are not expressly approved by MAN.
If changes are made without the written consent of MAN, the guarantee or warranty obligation for MAN is
not longer valid for damage and defects, which are based on these unauthorised changes. Furthermore
MAN assumes no liability for any damage caused as a result of unauthorised changes.
2.4 Responsibility of the Operator
The operator of the motor is subject to the statutory requirements for workplace safety.
In addition to the Safety Instructions in these Operating Instructions, the safety regulations, accident pre
vention regulations and environmental protection regulations valid for the application area of this engine
must also be observed.
In particular:
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 at the
operating site of the engine. He must then implement these safety regulations in the form of operating
instructions for the operation of the engine.
S During the entire period of operation of the engine the operator must check whether the operating in
structions he created meet the most current standards for regulations and revise them if necessary.
S The operator must clearly define and regulate the responsibilities for installation, operation, maintenance
and cleaning of the product.
S The operator must ensure that all staff who deal with the engine have read and understood the Operat
ing Instructions.
In addition, the operator must periodically train the staff and inform them about hazards.
S The operator must provide the personnel with the necessary protective equipment.
S These operating instructions must be kept in the immediate vicinity of the engine and be readily access
ible at any time to those persons working on and with the engine.
The operator is responsible for ensuring that the engine is always operated in perfect working condition and
working order.
In particular:
S Maintenance work such as that described in the Maintenance Instructions are to be completely per
formed within the prescribed time intervals or are to be performed by a MAN service workshop/MAN
contract partner.
S The operator must have all safety equipment checked regularly for function and integrity.
S The instructions in the Operating Instructions are to be followed completely and fully!
14
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.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.5 Personnel Requirements
2.5.1 Qualifications
WARNING!
Risk of injury caused by insufficient qualifications!
Improper handling can result in significant personal injury and property damage
For this reason:
S Specific activities must only be performed by those persons who are named in the re
spective chapters in these Operating Instructions.
The following qualifications will be designated in the Operating Instructions for various task areas.
S Instructed Persons
Have been instructed in a briefing about the possible dangers of improper handling in their tasks.
S Qualified Personnel
Due to their technical training, knowledge and experience and knowledge of the relevant regulations
they can properly perform the tasks assigned to them.
S Electric Specialist
Is capable of performing 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 any possible dangers.
The electric specialist is trained for the specific operating site in which he/she works and knows the rel
evant standards and regulations.
Only those people who can perform their work reliably should be considered as authorised personnel. Indi
viduals whose responsiveness is influenced, for example, by alcohol or drugs, are not permitted.
S When selecting personnel, observe the regulations regarding age and profession valid at the operating
site.
2.5.2 Unauthorised Persons
WARNING!
Danger for unauthorised persons!
Unauthorised persons who do not fulfil the requirements described here do not realise the
dangers that exist in the working area.
For this reason:
S Keep unauthorised persons out of the working area.
S In case of doubt, address the person and remove him/her from the working area if neces
sary.
S Interrupt the work until all unauthorised persons are out of the working area.
2.5.3 Instructions
Personnel must be instructed on regular basis and this should be documented in a log to keep better track
of who and when.
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.
15
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.6 Personal Protective Equipment
Wearing personal protective equipment is necessary to minimise the health risks when working.
SThe required personal protective equipment for the relevant job must always be worn while working.
S All signs pertaining to personal protective equipment in the working area must be followed.
Protective Clothing
Close-fitting clothing with low initial tear strength, 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.
Protective Helmet
To protect the head from falling or flying objects.
Safety Shoes
To protect the feet from heavy falling objects and from slipping on slick surfaces.
Safety Gloves
To protect the hands from friction, scraping, punctures or deep injuries and to protect
from hot or caustic parts or fluids
To be worn when performing specific types of work
When performing certain types of work, special protective equipment is required. These will be specifically
mentioned in the relevant chapters.
Safety Glasses
To protect the eyes from flying objects and spraying fluids.
Hearing Protection
16
To protect the ears from damage by loud noises.
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.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.7 Specific Dangers
The following section describes residual risks which have been identified.
S Observe the safety instructions listed here and the warnings in the other chapters of these instructions
in order to reduce health hazards and avoid dangerous situations.
Electrical Current
DANGER!
Risk of death caused by electrical current!
There is a risk of death when coming into contact with parts conducting electrical currents.
Damaged insulation or components can be life threatening.
For this reason:
S If the insulation is damaged, immediately switch off the power supply and get the insula
tion repaired.
S Any work performed on the electrical system may only be made by a qualified 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, cleaning or repair work the power supply must be
switched off and secured from being accidentally switched back on.
S Do not bridge or bypass any fuses. When replacing fuses, ensure to use the correct am
perage.
S Keep moisture clear of parts conducting electrical current. This could cause a short-cir
cuit.
Moving Parts
WARNING!
Risk of injury caused by moving parts!
Rotating or linear moving parts can cause serious injuries.
For this reason:
S During operation do not reach into or tamper with moving parts.
S Do not open the covers during operation.
S Observe the run-on time: before opening any covers ensure that no parts are still moving.
S Wear close-fitting clothing in the hazard area.
Multi-engine plants
WARNING!
Risk of injury caused by engines!
Persons in the operating room are at a risk if engine damage occurs.
For this reason:
S Limit the time spent in the operating room to the absolute minimum.
S Set up protective partitions to isolate running engines.
S Access to the operating room may only be made when engine is running at a light load.
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.
17
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
Exhaust gases
WARNING!
Risk of health hazard caused by exhaust gases!
Leaks in the exhaust system can cause dangerous exhaust gases to leak into the engine
room.
For this reason:
S Ensure sufficient ventilation.
S Immediately shut down engines with exhaust leaks.
Highly Flammable Substances - Diesel Fuel, Oils and Grease
WARNING!
Risk of fire caused by highly flammable substances!
Highly flammable substances, fluids or gases can catch on fire and cause serious or deadly
injuries.
For this reason:
S Do not smoke in the hazard area or in the vicinity.
No open fires or sources of ignition.
S Keep fire extinguishers at hand.
S Immediately report any suspicious substances, fluids or gases to the 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 hazardous to health
Coolants contain substances that are hazardous to your health. Contact with these sub
stances can lead to serious poisoning, allergies, skin irritations and damage to eyes.
For this reason:
S Observe the safety sheets from the manufacturer.
S Always wear protective clothing, chemical-resistant protective gloves and safety glasses.
S Avoid spilling or spraying these substances.
Hot Fluids and Lubricants
WARNING!
Risk of burns caused by hot fluids and lubricants!
Fluids and lubricants can reach high temperature while in operation and cause burns when
coming into contact with them.
For this reason:
S Before handling any fluids and lubricants, check whether they are hot. If necessary, let
them cool down first.
18
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.
Hot Surfaces
Noise
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
CAUTION!
Risk of burns caused by hot surfaces!
Contact with hot components can cause burns.
For this reason:
S When performing any work in the vicinity of hot components always wear protective cloth
ing and protective gloves.
S Before starting any work ensure that all components have cooled down to ambient tem
perature.
WARNING!
Risk of hearing damage caused by noise!
The level 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 area when work is fin
ished.
Sharp Edges and Corners
CAUTION!
Risk of injury cause by sharp edges and corners!
Sharp edges and corners can cause cuts and scrapes to the skin.
For this reason:
S Always work carefully and with caution in the vicinity of sharp edges and corners.
S In cases of doubt, wear protective gloves.
Dirt and Objects
CAUTION!
Risk of tripping caused by dirt and objects!
Dirt and objects can cause a person to slip or trip which can cause considerable injuries.
For this reason:
S Always keep the work area clean.
S Remove any objects that are no longer necessary.
S Mark areas where there is a danger of tripping with yellow and black striped tape.
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.
19
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.8 Safety Equipment
The operator must have the following safety equipment in place:
Before the engine is placed into operation, install the emergency-off equipment and connect it into the
safety chain of the system.
Connect the emergency-off equipment so that dangerous 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.
WARNING!
Risk of death caused by non-operational safety equipment!
Safety equipment ensures maximum safety during operation. Even if they may make work
ing more complicated, they must not be overridden. Safety can only be guaranteed if the
safety equipment is intact and operational.
For this reason:
S Before starting any work, check whether all of the safety equipment is correctly installed
and in good operating order.
S Before starting the engine, check whether all of the safety equipment is correctly installed
and in good operating order.
20
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.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.9 Conduct in Dangerous Situations and When Accidents Occur
Preventative Measures
S Always be prepared for an accident!
S Keep first aid equipment (first aid kit, blankets, etc.) and fire extinguishers at hand.
S Check first aid equipment and fire extinguishers regularly for completeness and proper operation.
S Familiarise the personnel with the emergency, first aid and rescue equipment.
S Instruct the personnel on safety on a regular basis.
S Always keep access lanes for rescue vehicles free of any obstructions.
In the case of an accident: Act accordingly
S Remain calm.
S Immediately shut down engine using the emergency-off button.
S Start first aid measures.
S Alert rescue services and/or fire department.
S Move people out of the danger zone.
S Clear access lanes for rescue vehicles.
S Inform the person in charge.
CAUTION!
Accidents despite preventative measures
If an accident occurs, e.g. from one of the listed points below, despite all of the preventative
measures, contact a physician immediately.
S Contact with caustic acids.
S Penetration of fuel into the skin.
S Scalding by hot oil or coolant.
S Antifreeze sprayed into the eyes, etc..
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.
21
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.10 Signs
The following symbols should be installed in the immediate vicinity of the hazard area.
WARNING!
Risk of injury caused by illegible symbols!
Stickers and symbols can become dirty or made otherwise illegible in the course of time!
For this reason:
S Always keep the safety, warning and operational signs in good legible condition.
S Clean or replace illegible safety, warning and operational signs.
Electric Voltage
Rooms marked with this symbol may only be accessed by qualified electricians.
Unauthorised persons may not enter these rooms.
Hot Surfaces
Hot surfaces such as hot engines and hot fluids may not always be recognisable. Do not
touch these surfaces without protective gloves.
22
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.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
2.11 Environmental Protection
CAUTION!
Environmental hazard caused by incorrect handling!
Incorrect handling of environmentally hazardous substances, especially when incorrectly
disposed of, can cause considerable damage to the environment.
For this reason:
S Always heed the information below.
S If environmentally hazardous substances are accidentally released 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:
Lubricants
Lubricants such as grease and oils contain poisons and environmentally hazardous substances. They must
not be allowed to be released into the environment. Disposal must be performed by a qualified disposal
company.
Diesel Fuel
Diesel fuel contains poisons and environmentally hazardous substances. They must not be allowed to be
released into the environment. Disposal must be performed by a qualified disposal company
Coolants
Coolants can contain poisons and environmentally hazardous substances. They must not be allowed to be
released into the environment. Disposal must be performed by a qualified disposal company.
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.
23
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
General Safety Instructions
24
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.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
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).
For this reason before the engine is commis
sioned, read off and enter in the data from the en
gine model plates below.
The engine model plates (1) and (2) are mounted
to the crankcase.
Engine Model Plate
MAN Nutzfahrzeuge Aktiengesellschaft
Typ
Motor-Nr. / Engine No.
NI/II
Model (3)
......................................................................
Engine number (4)
......................................................................
Work number/Job number (5)
......................................................................
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.
25
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Engine Model Plate
3.1 Explanation of the Motor-Nr./Engine-No. (Engine Identification Number)
Motor-Nr./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 Model Designation
Model designation Explanation Example
D Fuel type Diesel
28 Figure + 100 128 mm bore
4 Stroke figure (rounded) 142 mm stroke
8 / 0 / 2 Number of cylinders 8, 10, 12 cylinders
L Charging With charger and
intercooling
E Engine installation Installation engine
201/203/211/213 Model designation identification Development number
26
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.
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Design and Function
4 Design and Function
4.1 Engine, General
The 8, 10 and 12-cylinder engines described here are liquid-cooled, 4-cycle diesel engines with turbochar
ging and charge air cooling.
Engine Monitoring
Monitoring of the engine is made through various sensors. The sensors are designed, for example, as rpm
and temperature sensors, which report the various operating conditions of the engine to the engine control
unit. The engine control unit operates according to the EVA principle:
E = Eingang (Input)
V = Verarbeitung (Processing)
A = Ausgang (Output)
The engine control units process the information received from the sensors and control the output signals
which are sent to the actuators. The actuators convert the signals into mechanical factors.
Engine Lubrication
Pressure feed lubrication with one lube-oil pump for the bearings of the crankshaft, connecting rods and
camshafts as well as piston pin sockets, roller tappets and rocker arms.
Oil is filtered through a filter module with an integrated oil cooler and a crankcase breather in the main flow.
Ancillary assemblies such as high-pressure pump, turbocharger and PTOs are connected to the engine oil
circuit.
Cooling System
The cooling circuit is a thermostat controlled forced circulation cooling system. The maintenance-free
coolant pump is mounted to front side on the crankcase and is belt driven. The thermostats are located on
the coolant pump and are made with changeable disks.
Intake and Exhaust System
The dry exhaust pipes are mounted to the cylinder heads. The exhaust is routed to the turbocharger from
the high-pressure stage.
Control of the wastegate valves is made directly by the boost pressure. The engine's main-flow oil circuit
supplies the lubrication for the turbocharger and is connected at the oil pressure connections on the tur
bochargers.
The intake air is routed through the air filter to the turbochargers. The pre-compressed charge air is then
routed to the engine.
Fuel System, General
The fuel system is divided into a low-pressure and a high-pressure system.
The fuel lines, manual pump and the fuel filters are all part of the low-pressure system.
The fuel feed pumps that are flange-mounted to the high-pressure pump act as the interface to the highpressure system.
The high-pressure system consist of the high-pressure pump which is fed by the flange-mounted delivery
pumps and the high-pressure lines and injection nozzles.
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.
27
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Design and Function
4.2 Engine Views
4.2.1 Front Left View
1 2 3 4
(1) Fan
(2) Alternator
(3) Oil filler neck
(4) Turbocharger
(5) Starter
(6) Exhaust pipe
(7) Tensioning pulley
567
28
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.
4.2.2 Rear Right View
8 9 10
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Design and Function
(8) Crankcase breather
(9) Combustion air line from charge air cooler
(10) Combustion air line to charge air cooler
(11) Coolant pump
(12) Tensioning pulley
(13) Oil drain plug
(14) Oil cooler
(15) Oil filter
1112131415
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.
29
MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213
Design and Function
30
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.
Loading...