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:	[e-mail]
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	3
	and the safety instructions in each of the chapters.

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	5
	and the safety instructions in each of the chapters.

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

1Preface

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.

1.1.1Publications 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.

1.1.2Additional 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	7
	and the safety instructions in each of the chapters.

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:

SFailure to follow these instructions

SImproper use

SUse of untrained personnel

SCustomer conversions

STechnical modifications

SUse 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	9
	and the safety instructions in each of the chapters.

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:

SOnly 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:

SSort metals before scrapping

SRecycle plastic parts

SDispose of all other parts according to their material composition

		Carefully read the Operating Instructions before starting any work!
	10	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	11
	and the safety instructions in each of the chapters.

MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213

Foreword

		Carefully read the Operating Instructions before starting any work!
	12	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

2General 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:

SUse the engine for its intended purpose only.

SUse the engine outside of hazardous areas where there is a risk of explosion.

SUse the engine with an overspeed limiting device installed.

NOTE!

Observe the following information when operating the engine:

SThe safety information in these Operating Instructions and in the supplier's operating in­ structions.

SThe “Technical Data" chapter in these Operating Instructions and in the supplier's operat­ ing instructions.

SCountry-specific regulations.

	Carefully read the Operating Instructions before starting any work!
	This is especially valid for the chapter on General Safety Instructions	13
	and the safety instructions in each of the chapters.

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:

SThe 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.

SDuring 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.

SThe operator must clearly define and regulate the responsibilities for installation, operation, maintenance and cleaning of the product.

SThe 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.

SThe operator must provide the personnel with the necessary protective equipment.

SThese 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:

SMaintenance 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.

SThe operator must have all safety equipment checked regularly for function and integrity.

SThe instructions in the Operating Instructions are to be followed completely and fully!

		Carefully read the Operating Instructions before starting any work!
	14	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

2.5.1Qualifications

WARNING!

Risk of injury caused by insufficient qualifications!

Improper handling can result in significant personal injury and property damage

For this reason:

SSpecific 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.

SInstructed Persons

Have been instructed in a briefing about the possible dangers of improper handling in their tasks.

SQualified Personnel

Due to their technical training, knowledge and experience and knowledge of the relevant regulations they can properly perform the tasks assigned to them.

SElectric 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.

SWhen selecting personnel, observe the regulations regarding age and profession valid at the operating site.

2.5.2Unauthorised 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:

SKeep unauthorised persons out of the working area.

SIn case of doubt, address the person and remove him/her from the working area if neces­ sary.

SInterrupt the work until all unauthorised persons are out of the working area.

2.5.3Instructions

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	15
	and the safety instructions in each of the chapters.

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.

SAll 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

To protect the ears from damage by loud noises.

		Carefully read the Operating Instructions before starting any work!
	16	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.

SObserve 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:

SIf the insulation is damaged, immediately switch off the power supply and get the insula­ tion repaired.

SAny work performed on the electrical system may only be made by a qualified electrician.

SWhen working on the electrical system the power supply must be switched off and then properly checked to ensure no electrical current is present.

SBefore starting any maintenance, cleaning or repair work the power supply must be switched off and secured from being accidentally switched back on.

SDo not bridge or bypass any fuses. When replacing fuses, ensure to use the correct am­ perage.

SKeep 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:

SDuring operation do not reach into or tamper with moving parts.

SDo not open the covers during operation.

SObserve the run-on time: before opening any covers ensure that no parts are still moving.

SWear 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:

SLimit the time spent in the operating room to the absolute minimum.

SSet up protective partitions to isolate running engines.

SAccess 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	17
	and the safety instructions in each of the chapters.

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:

SEnsure sufficient ventilation.

SImmediately 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:

SDo not smoke in the hazard area or in the vicinity.

No open fires or sources of ignition.

SKeep fire extinguishers at hand.

SImmediately report any suspicious substances, fluids or gases to the person in charge.

SIn 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:

SObserve the safety sheets from the manufacturer.

SAlways wear protective clothing, chemical-resistant protective gloves and safety glasses.

SAvoid 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:

SBefore handling any fluids and lubricants, check whether they are hot. If necessary, let them cool down first.

		Carefully read the Operating Instructions before starting any work!
	18	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

Hot Surfaces

CAUTION!

Risk of burns caused by hot surfaces!

Contact with hot components can cause burns.

For this reason:

SWhen performing any work in the vicinity of hot components always wear protective cloth­ ing and protective gloves.

SBefore starting any work ensure that all components have cooled down to ambient tem­ perature.

Noise

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:

SAlways wear hearing protection when working.

SDo 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:

SAlways work carefully and with caution in the vicinity of sharp edges and corners.

SIn 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:

SAlways keep the work area clean.

SRemove any objects that are no longer necessary.

SMark 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	19
	and the safety instructions in each of the chapters.

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:

SBefore starting any work, check whether all of the safety equipment is correctly installed and in good operating order.

SBefore starting the engine, check whether all of the safety equipment is correctly installed and in good operating order.

		Carefully read the Operating Instructions before starting any work!
	20	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

SAlways be prepared for an accident!

SKeep first aid equipment (first aid kit, blankets, etc.) and fire extinguishers at hand.

SCheck first aid equipment and fire extinguishers regularly for completeness and proper operation.

SFamiliarise the personnel with the emergency, first aid and rescue equipment.

SInstruct the personnel on safety on a regular basis.

SAlways keep access lanes for rescue vehicles free of any obstructions.

In the case of an accident: Act accordingly

SRemain calm.

SImmediately shut down engine using the emergency-off button.

SStart first aid measures.

SAlert rescue services and/or fire department.

SMove people out of the danger zone.

SClear access lanes for rescue vehicles.

SInform 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.

SContact with caustic acids.

SPenetration of fuel into the skin.

SScalding by hot oil or coolant.

SAntifreeze 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	21
	and the safety instructions in each of the chapters.

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:

SAlways keep the safety, warning and operational signs in good legible condition.

SClean 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.

		Carefully read the Operating Instructions before starting any work!
	22	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:

SAlways heed the information below.

SIf 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	23
	and the safety instructions in each of the chapters.

MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213

General Safety Instructions

		Carefully read the Operating Instructions before starting any work!
	24	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

Engine Model Plate

3Engine 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.

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	25
	and the safety instructions in each of the chapters.

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

		Carefully read the Operating Instructions before starting any work!
	26	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

4Design 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	27
	and the safety instructions in each of the chapters.

MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213

Design and Function

4.2 Engine Views

4.2.1Front Left View

1

2

3

4

7

6

5

(1)Fan

(2)Alternator

(3)Oil filler neck

(4)Turbocharger

(5)Starter

(6)Exhaust pipe

(7)Tensioning pulley

		Carefully read the Operating Instructions before starting any work!
	28	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

4.2.2Rear Right View

8

9

10

15

14

13

12

11

(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

	Carefully read the Operating Instructions before starting any work!
	This is especially valid for the chapter on General Safety Instructions	29
	and the safety instructions in each of the chapters.

MAN Industrial Diesel Engines D2848/40/42 LE201/203/211/213

Design and Function

		Carefully read the Operating Instructions before starting any work!
	30	This is especially valid for the chapter on General Safety Instructions
		and the safety instructions in each of the chapters.