Operating Instruction: MAN Industrial Diesel Engines D2862 LE221/223/231/233

Operating Instruction
MAN Industrial Diesel Engines

D2862 LE221/223/231/233
MAN Engines
Operating Instructions
MAN Industrial Diesel Engines

D2862 LE221 / LE223 / LE231 / LE233
51.99587-5144 “Original instruction”

Version 01
Information and Copyright
Subject to modifications
The information, text, drawings, pictures and other illustrations that it contains are protected by copyright
and are subject to industrial property rights. Anx misuse is punishable by law.
It is not permitted to change the contents of this document. The same applies to changes to the context of
individual chapters and/or the whole document. MAN Truck & Bus assumes no liability for any damages
arising from non-compliance with the above provisions.
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.
© 2019
MAN Truck & Bus SE
Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
Email: Engine-Documentation@man.eu
Internet: www.engines.man.eu
Technical status: 09.2017

51.99587-5144
Carefully read the Operating Instructions before starting any work!

This is especially valid for the chapter on General Safety Instructions
2 and the safety instructions in each of the chapters.
List of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information on the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.1 Publications, which relate to the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.2 Supplementary documentation for the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Restriction of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Applicable documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Content of the operating instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Alterations and modifications on 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 Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Personal protection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Special dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8.1 Emergency-Stop facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8.2 Belt guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8.3 Protective cover for fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8.4 Heat shields for exhaust pipes and turbine housings . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.9 Behaviour in the event of dangerous situations and accidents . . . . . . . . . . . . . . . . . . . . . . . 23
2.10 Signs and notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.11 Protection of the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Explanation of Motor-Nr./ Engine No. (Engine identification number) . . . . . . . . . . . . . . . . . 28
3.2 Explanation of type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

and the safety instructions in each of the chapters. 3
List of contents
4 Construction and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.1 View front, left, with cooling system and air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.2 View front, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.3 View front, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2.4 View front, left, with Duralite air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2.5 View front, right, with Duralite air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Transport, packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3 Installation - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.1 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.2 Data on the engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.1 Filling with diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.2 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4.3 Leakage check of entire cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

List of contents
7 Handling and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3 Preparation before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.3.1 Check fuel contents and top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.3.2 Check coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.3.3 Top up with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.3.5 Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3.6 Top up with engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.4.1 Operation monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.4.2 Stopping in the event of an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8 Care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.1 Maintenance instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.1.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.1.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.2 Repair instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.3 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10 Decommissioning and Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.3 Temporary decommissioning of an engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.4 Recommissioning of decommissioned engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.4.1 Commissioning of preserved engines in accordance
with MAN-Werknorm M 3069 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.4.2 Commissioning of non-preserved engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

List of contents
11 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.1.1 With cooling system (MAN scope of delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.1.2 With Duralite air filter (without cooling system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.2 Requirements of the installation site, space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.3 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.3.1 D2862 LE221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.3.2 D2862 LE223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11.4 Coordinates of the center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.4.1 D2862 LE223 (without air filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11.4.2 D2862 LE223 (with air filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12.2 Technical terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12.3 List of key words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
13 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Foreword
1 Introduction
1.1 Information on the 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, which relate to the operating instructions

The following documents relate directly to the operating instructions:
- Fluids and lubricants for MAN Diesel Engines
- Maintenance instructions
- Installation instructions
All documents are components of the product and must be kept in the immediate vicinity of the engine and
accessible at all times to 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 Supplementary documentation for the engine

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

Foreword
1.2 Explanation of symbols
Warnings
Warnings are identified in these Operating Instructions with symbols. These warnings are prece
ded 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.

Foreword
1.3 Restriction of liability

All of the information in these instructions has 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 wor
king with the engine. Transfer to a third party without explicit written permission from MAN is strictly prohibi
ted.
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 Applicable documentation

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.

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 appro
ved 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 observations.
WARNING!
Risk of injury from incorrect spare parts!
Incorrect or faulty spare parts can lead to damage, malfunctions or total failures and in
terfere with safety.
For this reason:
S Only use MAN genuine parts
NOTE!
Please always specify the engine model, engine number and order number when corre
sponding with MAN, see page 27.
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

Foreword
1.8 Warranty conditions

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 the use of genuine parts even after the warranty period has passed. This will ensure the
continuous performance of the engine.
1.9 Customer service

Our MAN product support is available for technical information.
NOTE!
Please always specify the engine model, engine number and order number when corre
sponding with MAN, see page 27.
Information about contact persons can always be called up by telephone, email or via the Internet. For
addresses see page 2.

Foreword

General Safety Instructions
2 General Safety Instructions

This chapter provides information on residual risks and hazards during proper use of the engine. The gene
rally valid safety instructions to be observed are listed here. They provide optimum protection for personnel
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 signifi
cant hazards.
2.1 Intended use

The engine variation LE221 is built for the purpose of emergency power operation (LTP) and peak load
operation (PRP), The engine variation LE231 only for peak load operation (PRP) and the engine variations
LE223 and LE233 for emergency standby power (ESP).
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 Only use the engine for its intended purpose.
S The engine is only to be operated outside hazardous areas (Ex-zones).
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 opera
ting instructions.
S Country-specific regulations.

2.2 Content of the operating instruction

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 Alterations and modifications on 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 Opera
ting 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 accessi
ble 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 and fully!

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 rele
vant 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 ne
cessary.
S Interrupt the work until all unauthorised persons are out of the working area.
2.5.3 Instruction
Personnel must be instructed on a regular basis and this should be documented in a log to keep better
track of who and when.

2.6 Personal protection equipment

Wearing personal protective equipment is necessary to minimise the health risks when working.
S The 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
To protect the ears from damage by loud noises.

2.7 Special 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 insu
lation 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 swit
ched 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 plant
WARNING!
Risk of injury due to engines in the vicinity!
In the event of damage to an engine persons in the operating area can be endangered.
For this reason:
S Limit time spent in the engine area to the absolute minimum.
S Provide protection safety devices on running engines.
S Personnel are only permitted to remain in the operating area during low load operation of
the engines.

Exhaust gases
WARNING!
Risk to health due to exhaust gases!
Dangerous exhaust gases can be present in the machine room in the event of lack of se
aling in the exhaust system.
For this reason:
S Ensure sufficient ventilation.
S Machines having leaking exhaust systems must be shut down immediately.
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.

Hot Surfaces
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 clo
thing and protective gloves.
S Before starting any work ensure that all components have cooled down to ambient tempe
rature.
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:
S Always wear hearing protection when working.
S Do not unnecessarily remain in the hazard area. Leave hazard area when work is finis
hed.
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.

Working on the Common Rail System
WARNING!
Risk of injury caused by fluids exiting under high pressure!
Fuel lines under high pressure (1800 bar) can cause considerable injuries.
For this reason:
S Work on the common rail system must only be performed by trained and qualified per
sonnel.
S Before starting any work on the common rail system the engine must be switched off.
Wait until the pressure in the system has been released.
WARNING!
Risk of death caused by spraying fluids!
Fluid can exit under high pressure from faulty lines or machine components.
The exiting fluids can sever body parts which leads to serious injuries or death.
For this reason:
S Never touch the stream of an exiting fluid.
S Immediately press the emergency off button. If necessary perform further measures to
reduce the pressure of the exiting fluid.
S Properly clean up and dispose of fluids that have exited the system.
S Get the faulty parts repaired.
WARNING!
Risk of death caused by hydraulic power!
Hydraulic power can cause serious to deadly injuries.
Hydraulic powered parts can move unexpectedly.
If components are damaged, hydraulic fluid can exit under high pressure.
For this reason:
S Work on the hydraulic system must only be performed by trained and qualified personnel.
S Before starting any wok on the hydraulic system it must first be switched off and the
pressure released. The pressure reservoir must be completely depressurized. Check to
ensure there is no pressure in the system.
S Do not change the pressure setting above the maximum value.

WARNING!
Risk of death caused by strong magnetic fields!
Strong magnetic fields can cause serious injuries and death as well as considerable
property damage.
For this reason:
S Persons with cardiac pacemaker must not remain in the vicinity of the engine.
The operation of the cardiac pacemaker could be negatively affected.
S Persons with metal implants must not remain in the vicinity of the engine. Metal implants
could heat up or be attracted to the magnetic source.
S Keep ferromagnetic materials and electromagnets away from magnetic sources. These
materials can be magnetically attracted and can fly through the room and injure people or
cause death. Keep a minimum distance of 3 m.
S Take off all metal objects (jewellery, watches, pens, etc.) before starting any maintenance
work.
S Do not take any electronic devices near the magnetic source. They could be damaged.
S Dot not take any memory devices, credit cards, etc. near the magnetic source. Data could
be erased.

2.8 Safety devices
Before the engine is commissioned, the operator must fit the following safety devices:
WARNING!
Risk of death caused by non-operational safety equipment!
Safety equipment ensures maximum safety during operation. Even if they may make wor
king 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.
2.8.1 Emergency-Stop facility

Connect the emergency-stop equipment so that dangerous situations to people and property are avoided in
the event that the power supply is interrupted or is turned back on after an interruption.
The emergency-off equipment must always be freely accessible.
2.8.2 Belt guards

The belt drives of the generator and the fan must be fitted with guards in order to avoid dangerous situa
tions for persons, property and equipment.
2.8.3 Protective cover for fan

The fan must be provided with a protective cover in order to avoid dangerous situations for persons,
property and equipment.
2.8.4 Heat shields for exhaust pipes and turbine housings

Exhaust pipes and turbine housings must always be provided with suitable heat shields in order to avoid
dangerous situations for persons, property and equipment.

2.9 Behaviour in the event of dangerous situations and accidents
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..

2.10 Signs and notices

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.

2.11 Protection of the environment
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.


Engine Type Plate
3 Engine type plate
In all communications please always state the en

gine model (3), engine number (4) and work num
ber/job number (5).
For this reason, before the engine is com
missioned, read off and enter in the data from the
engine type plates below.
The engine type plates (1) and (2) are mounted on
the crankcase.
MAN Nutzfahrzeuge Aktiengesellschaft

Typ
Motor-Nr. / Engine No.
NI/II
Model (3)
......................................................................
Engine number (4)
......................................................................
Work number/Job number (5)
......................................................................

Engine Type Plate
3.1 Explanation of Motor-Nr./ Engine No. (Engine identification number)

Motor-Nr./Engine-No. Class identifier
(assignment)
711 Model number according to index of model codes
1234 Assembly date (Works internal reference)
547 Assembly order (sequence number on day of assembly)
8910 Production and equipment-specific data
3.2 Explanation of type designation

Model designation Explanation Example
D Fuel type Diesel
28 Figure + 100 128 mm bore
6 Stroke figure (rounded) 157 mm stroke
2 Number of cylinders 12 cylinders
Supercharging and
L Charging
Intercooling
Engine installation for power
E Engine installation
generation plants
2 = Engine equipment set
221/223/231/233 Model designation identification 2/3 = Common rail
1/3 = Serial number

Design and Function
4 Construction and function
4.1 Engine, general

The 12 cylinder engines described here are liquid-cooled 4-stroke diesel engines with exhaust gas turbo
charging and intercooling.
These engines operate with the high pressure Common Rail injection system in connection with EDC7
(Electronic Diesel Control).
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 unit processes the received sensor information and controls the output signals which
are sent to the actuators. The actuators convert the signals into mechanical factors.
One of the actuators, for example, is the metering unit on the high-pressure pump.
Engine Lubrication
Pressure feed lubrication with two lube-oil pumps 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 two filter modules with an integrated oil cooler and crankcase breather in the main
circuit. Ancillary assemblies such as high-pressure pump, coolant pump drive, turbocharger and power
take-offs are connected to the engine lube-oil circuit.
Cooling System
The cooling circuit is a thermostatically-controlled forced-flow cooling system. The maintenance free coo
lant pump is installed at the front side under the cover and is driven by an uncoupled set of gears. The
thermostats are installed in the two-part thermostat housing.
The thermostats consist of a changeable insert with expansion element.
Intake and Exhaust System

The dry exhaust pipes are attached to the cylinder head. The exhaust gases pass from the exhaust system
into the exhaust turbocharger.
The lubrication of the exhaust turbocharger takes place via the main oil circuit of the engine to the oil
pressure connection on the turbocharger.
The intake air passes via the air filter to the exhaust turbocharger. The now pre-compressed charge air is
cooled in the intercooler and then passed 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 interface to the high pressure system is the fuel pre-delivery pumps, flange-mounted on the flow-con
trolled high-pressure pumps.
The high pressure system comprises the two flow-controlled high pressure pumps, which are supplied from
the respective flange-mounted pre-delivery pumps, together with fuel filter, pipelines (rail) and injectors.

Design and Function
4.2 Engine views
4.2.1 View front, left, with cooling system and air filter
(1) Coolant-compensating reservoir (8) Oil dipstick

(2) Coolant filler tube (9) Charge air pipe
(3) Air filter (10) Coolant pipe
(4) Air filter (11) Coolant radiator
(5) Intake hose (12) Intercooler
(6) Oil filler (13) Sealing cap
(7) Fuse casing

Design and Function
4.2.2 View front, left
(1) Air filter (10) Alternator

(2) Manual feed pump (11) Belt tensioner
(3) Exhaust turbocharger (12) Oil separator
(4) Starter (13) Pusher fan
(5) Oil filler (14) Oil separator
(6) Oil pan (15) Oil filter
(7) Fuse box (16) Charge air pipe
(8) Oil dipstick (17) Rail (left)
(9) Oil filter

Design and Function
4.2.3 View front, right
(1) Air filter (7) Pusher fan

(2) Air filter (8) Vibration damper
(3) Rail (right) (9) Oil separator
(4) Charge air pipe (10) Oil filter
(5) Oil filter (11) Turbocharger
(6) Oil separator

Design and Function
4.2.4 View front, left, with Duralite air filter
(1) Air filter (10) Alternator

(2) Manual feed pump (11) Belt tensioner
(3) Exhaust turbocharger (12) Oil separator
(4) Starter (13) Pusher fan
(5) Oil pan (14) Charge air pipe
(6) Oil filler (15) Oil separator
(7) Oil dipstick (16) Oil filter
(8) Fuse box (17) Charge air pipe
(9) Oil filter (18) Rail (left)

Design and Function
4.2.5 View front, right, with Duralite air filter
(1) Air filter (7) Pusher fan

(2) Air filter (8) Vibration damper
(3) Rail (right) (9) Oil separator
(4) Charge air pipe (10) Oil filter
(5) Oil filter (11) Turbocharger
(6) Oil separator

Transport, Packaging and Storage
5 Transport, packaging and storage

It is absolutely necessary to observe the “Assembly Instructions” for the installation and commissioning of a
new or reconditioned engine.
NOTE!
Installation and commissioning is only to be made by the employees of the manufacturer of
the entire system or by manufacturer authorised personnel.
Nevertheless, as part of the installation and the use of the engine, situations will occur
where the operator or his maintenance personnel will have to be familiar with the handling
of packages. In these situations it is absolutely necessary to observe the following informa
tion.
5.1 Prerequisite
Before starting any work read and observe the General Safety Instructions and the safety information in this
chapter.
Strictly observe these instructions and act prudently to avoid accidents, personal injury and property damage.
Personal Protective Equipment

The following protective equipment must be worn:
S Protective Clothing
S Protective Helmet
S Safety Shoes
S Safety Gloves
5.2 Safety instructions
Heavy Suspended Loads
WARNING!
Risk of death caused by heavy suspended loads!
During lifting operations loads may swing and fall. This may cause serious injury and even
death.
For this reason:
S Do not stand under or remain in the swivel range of the suspended load.
S Only move the load under supervision.
S Only use approved lifting equipment and accessories with sufficient load capacity.
S Never use torn or scuffed lifting equipment such as ropes or straps.
S Do not let lifting equipment such as rope or straps come into contact with sharp edges
and corners and do not twist or knot them.
S Before leaving the work area, lower load to ground.

Off-Centre Point of Gravity
WARNING!
Risk of injury caused by falling or tipping packages!
Packages can have a centre of gravity that is off-centre. If the lifting equipment is not hoo
ked up properly, these packages could tip over and fall causing serious injuries.
For this reason:
S Observe the information and markings on the package concerning centre of gravity.
S When transporting with a crane, the hook must be placed so that it is directly above the
package's centre of gravity.
S Carefully raise the package and observe its movement. If necessary, change the position
of the lifting equipment.
Swinging out of Packages being Transported
WARNING!
Risk of injury caused by packages swinging out during transportation!
When transporting the packages with a crane, the packages can swing out and cause
serious injuries and significant property damage.
For this reason:
S Ensure that during the transport of packages, no persons, objects or obstacles are in the
swivel range of the packages being transported.
Unauthorised Transport
IMPORTANT!
Risk of property damage if packages are transported by untrained personnel!
Unauthorised transport by untrained personnel can cause packages to fall or tip over. This
could cause considerable property damage.
For this reason:
S Unloading of packages during delivery and their in-house transport are only to be per
formed by trained personnel under the supervision of the manufacturer's employees.
S Refrain from any unauthorised transportation or removal of the transportation aids.
S No unauthorised removal of packaging permitted.
Improper Transport
IMPORTANT!
Risk of property damage caused by improper transport!
Improper transport can cause packages to fall or tip over. This could cause considerable
property damage.
For this reason:
S Carefully handle the packages when unloading during delivery and when transporting
them within the company. Observe the symbols and instructions on the packages.
S Only use the prescribed lifting points.

5.3 Transport inspection

Check the delivery for missing items and for damage from transport.
If external signs of transport damage are apparent:
S Do not accept delivery or only accept under written protest.
S List scope of damage on the transport documents or on the transportation company's packaging slip.
S Initiate a claims process.
NOTE!
Make sure to claim each damage case as soon as it is discovered. Damage claims can only
be claimed within the applicable time limits.

5.4 Transport
Lifting Points
There are 3 lifting lugs (1) for the crane installed on the engine.
WARNING!
Risk of death caused by the load falling!
During lifting operations, loads can fall down. This can cause serious injury and even death.
For this reason:
S The „crane lifting lugs“ are only to be used to transport the engine with no ancillary
assemblies attached.

Transport with Crane

The engine can be transported with a crane under the following conditions.
S The crane and the lifting equipment must be designed for the weight of the engine.
S The operator must be qualified for operating the crane.
1. Attach the ropes, straps or multipoint lifting equipment as shown in the illustration.
2. Ensure that the package is hanging straight or compensate for the off-centre point of gravity.
3. Start the transport.
Transport with Forklift

The engine can be transported using a fork lift truck under the following conditions:
S The forklift must be designed for the weight of the engine.
S The engine must be securely mounted to the pallet.
S The fork lift driver must be qualified and authorised to drive the fork lift truck .
1. Insert the fork of the forklift between or under the pallet's struts.
2. The fork must be inserted into the pallet until it protrudes from the other side.
3. Ensure that the pallet cannot tip over if the centre of gravity is off-centre.
4, Lift the pallet and transport it to the desired location.

5.5 Packaging
Packaging
The individual packages are packed in accordance with the expected conditions of transport.
The purpose of the packaging is to protect the components from transport damage, corrosion and other
damage. For this reason do not unpack components until shortly before they are to be assembled.
Handling Packing Material

Dispose of packing material according to the valid local and statutory regulations.
IMPORTANT!
Risk of hazard to the environment caused by incorrect disposal!
Packaging materials are valuable raw materials and can in many cases continue to be used
or can be processed and recycled. Incorrect disposal of packaging materials may cause an
environmental hazard.
For this reason:
S Dispose of packing materials in an environmentally friendly manner.
S Observe the valid local regulations. If necessary, contact a professional disposal com
pany.
5.6 Storage
Storage of packages
Store packages under the following conditions:
S Do not store in the open.
S Store in a dry and dust-free environment.
S Do not expose to damaging chemicals.
S Protect from sun light.
S Avoid any physical shocks.
S Storage temperature: 15 to 35 °C.
S Relative humidity: max. 60 %.
S If stored for more than 3 months, regularly check the condition of the packaging. If necessary, renew or
replace the preservation.
NOTE!
Some of the packages may have information printed on them regarding their proper sto
rage. Please observe this information.

Installation and Commissioning
6 Installation and Commissioning
6.1 Prerequisite
chapter.

S Safety Shoes
S Safety Gloves
Personnel
S The installation and commissioning may only be performed by MAN employees or by MAN-trained quali
fied personnel.
WARNING!
Danger caused by faulty installation and commissioning!
Installation and commissioning require trained qualified personnel with sufficient experi
ence. Faulty installation can cause life threatening situations and considerable property
damage.
For this reason:
S Installation and commissioning are only to be performed by MAN employees.
S Installation and commissioning by MAN trained qualified personnel may only be per
formed with approval from MAN.
Ground Rules
WARNING!
Risk of injury caused by improper installation and commissioning!
Improper installation and commissioning can cause serious personal injury or considerable
property damage.
For this reason:
S Ensure adequate work space before starting any work.
S Be careful when working with exposed parts with sharp edges.
S Make sure work space is kept clean and orderly!
S Install components in a correct manner.
S Observe the prescribed tightening torques.
S Secure components so that they do not fall or tip over.
S Before commissioning the engine, carefully read the Operating Instructions and familiarise yourself with
the “critical” subjects.
S It is absolutely necessary to observe the “Assembly Instructions” for the installation and commissioning
of a new or reconditioned engine.

S For safety reasons the access to the engine bay is to be provided with an 'access prohibited' warning
sign and operating personnel instructed that this is a responsible action in ensuring the safety of per
sons who enter the engine bay.
6.3 Installation - Engine

The installation of the engine, i.e. the connection of the power supply and connection of the cooling system,
is to be carried out in accordance with information provided by the manufacturer of the overall plant and
using the “Assembly instruction” and the “Installation instruction”.
6.3.1 Safety devices
WARNING!
Risk of death caused by the absence of safety equipment!
An emergency-off button, for shutting down the system or engine in an emergency, must be
installed for each engine.
For this reason:
S Install an emergency stop button to shut down the system in an emergency.
S Check whether all of the safety equipment is correctly installed and in good operating
order.
WARNING!
On each engine the belt drives of the alternator and the fan must be fitted with protective
covers.
For this reason:
S Install belt guards on both drives.
order.
WARNING!
On each engine the fan must be provided with a cover.
For this reason:
S Provide a protective cover around the fan.
order.
WARNING!
On each engine the exhaust pipe and the turbine housing must be provided with a suitable
heat shield.
For this reason:
S Install heat protection shields.
order.

WARNING!
Risk of death caused by faulty operation!
In the event of overload or failure conditions the engine may overheat and suddenly lock.
For this reason:
S The sensors which monitor the engine parameters must be connected to and evaluated
by the module manufacturer's monitoring equipment.
S If sensor values go outside the permissible limits or if there is a power loss, the engine
must be able to be immediately shut off by the monitoring equipment.
6.3.2 Data on the engine type plate

Please always specify the engine model, engine number and order number when corresponding with MAN.
For this reason, before commissioning the engine, read off the data from the engine model plate and enter
it into the Engine Model Plate chapter, see page 27.

6.4 Commissioning
New and overhauled engines are not to be operated at greater than approx. 3/4 load during the initial ope
rating hours and at varying speed.
After this time period the engine can be slowly brought up to full power.
IMPORTANT!
Termination of liability for material defects by use of non-approved fluids and lubri
cants!
Liability of material defects is terminated if non-approved fluids and lubricants are used.
For this reason:
S Only use approved fluids and lubricants (see “Fluids and Lubricants ..." publication).
6.4.1 Filling with diesel fuel
DANGER!
Risk of fire caused by diesel fuel!
Diesel fuel is highly flammable.
For this reason:
S No smoking and no open fires when handling fuels.
S Only fill with fuel with the engine stopped.
S Ensure cleanliness.
S Do not let fuel drip or leak out.
IMPORTANT!
Component damage to injection system caused by water in diesel fuel!
Absolutely prevent any ingress of water.
For this reason:
S Install a prefilter and a water separator into the fuel supply.
1. Fill diesel fuel according to the instructions of the manufacturer of the entire system.
2. Open fuel shutoff valve.

6.4.2 Filling with coolant
IMPORTANT!
Coolant is damaging to the environment.
For this reason:
S When filling, the coolant must not be allowed to spill. No coolant must be allowed to con
taminated soil or water sources.
Special tools
[1] Connecting piece M26x1,5 51.981310279

SS Filling with coolant
Fill the cooling system of the engine with a mixture of tap water and ethylene glycol antifreeze agent or an
ticorrosion agent.
Only use approved Fuels, Lubricants and Coolants (see Publication “Operating fuels, lubricants and
coolants for MAN diesel engines”).
1. Unscrew the screw cap (1).

2. Unscrew and remove the cap with sealing
washer on the drain valve (2) and (3).
3 Screw on connecting piece [1] with a hose on
the drain valve (2) and (3). Place a container
with sufficient capacity under the end of the
hose.
For coolant filling capacity, see “Technical Data”
page 68.
4. Slowly add coolant at the filler neck until the
coolant starts to escape at the drain valve (2)
and (3).
5 Unscrew the connecting piece [1] with the hose
from the drain valve (2) and (3) and screw on
the cap with the sealing washer.
6. Continue to add coolant slowly until it reaches
the lower edge of the filler neck.
7. Screw the screw cap (1) back on.
8. Check the entire cooling system for leaks, see
page 46.
9. Start the engine and drive to warm it up; when
the engine temperature has reached 82 °C,
continue driving for another 15 minutes.
10.Stop the engine and let it cool down to below
60 °C.
11 If necessary, top up the coolant by adding it at
the filler neck (1) and bleed the engine coolant
circuit by means of the drain valve (2) and (3).

6.4.3 Leakage check of entire cooling system

To check whether cooling system is free from leaks, an air pressure connection
and a pressure gauge must be attached at the threaded connection for the level sensor.
Cooling system must be pressurized with an air pressure of 1.0 bar with the engine at a standstill. After the
air supply has been disconnected, the applied preliminary pressure of 1.0 bar must be held for at least
30 minutes.
If this is not the case, the cause of the leak must be located and eliminated.
Leaks caused by the valves on the expansion tank can be eliminated by applying some grease to the
rubber seal.Filling Engine Oil
IMPORTANT!
cants!
For this reason:
S Only use approved Fuels, Lubricants and Coolants (see Publication “Operating fuels,
lubricants and coolants for MAN diesel engines”).
IMPORTANT!
Component damage caused by
over filling!
Engine damage can occur if engine
oil is filled to above the max. mark
on the oil dipstick.
For this reason:
S Do not fill engine oil above the
max. mark on the oil dipstick
MAX
MIN
1. Remove cap (1).

2. Slowly fill engine oil into the filler opening.
For oil filling capacity, see “Technical Data”
page 68.
3. Reinstall cap (1).

Operation
7 Handling and operation
7.1 Prerequisite
chapter.

S Safety Shoes
S Safety Gloves
Personnel
S Operation of the engine may only be performed by instructed personnel or by trained qualified per
sonnel.
Ground Rules
WARNING!
Danger caused by faulty operation!
Improper operation can cause serious personal injury or considerable property damage.
For this reason:
S Perform all operating steps in accordance with the instructions in these Operating Instruc
tions.
S Before starting any work ensure that all covers and protective equipment have been in
stalled and are operating properly.
S Never shut off any safety equipment while in operation.
S Maintain good order and cleanliness in the work area! Components lying around or on top
of each other are a possible cause of persons tripping and falling.
WARNING!
Risk of injury caused by vapours!
During the initial hours of operation the paintwork on hot components can burn and let off
vapours that are injurious to health.
For this reason:
S Ensure sufficient ventilation.
S Limit time spent in the engine area to the absolute minimum.

Operation
Machines with automatic start sequence.
DANGER!
Danger of injury due to self-starting engines!
Rotating or linear moving parts can cause serious injuries.
For this reason:
S Moving parts must not be accessible during operation/readiness for operation.
S Display warning signs “Plant starts automatically”.
S Observe regional regulations.
7.3 Preparation before operation
DANGER!
Danger caused by damaged engines!
Damaged engines can be dangerous to persons.
For this reason:
S Check engine for damage and leaks before each operation.
S Do not operate engine if damage is found.
Before operation, check fuel supply, level of coolant and oil in the engine.
If necessary, refill diesel fuel, coolant and oil.
IMPORTANT!
cants!
For this reason:
S Only use approved fluids and lubricants (see “Fluids and Lubricants ..." publication).
7.3.1 Check fuel contents and top up
DANGER!
Risk of fire caused by diesel fuel!
Diesel fuel is highly flammable.
For this reason:
S No smoking and no open fires when handling fuels.
S Only refuel with engine off.
S Ensure cleanliness.
S Do not let fuel drip or leak out.
1. Check fuel supply and refuel in accordance with the instructions of the manufacturer of the entire sys
tem.
2. Open fuel shutoff valve.

Operation
7.3.2 Check coolant
WARNING!
Risk of scalding!
The cooling system is under pressure and the coolant is hot.
For this reason:
S Let engine cool down first
1. Remove cap (1).

2. Check coolant level.
The normal coolant level is at the bottom edge of
the filler neck.
If the coolant is too low, refill with coolant.
7.3.3 Top up with coolant

NOTE!
Do not let coolant drip or leak out while refilling. Do not let coolant leak out onto the ground
or into bodies of water otherwise this will cause damage to the environment.
IMPORTANT!
Engine damage caused by excessive temperature difference!
When topping up an engine still hot from operation with cold coolant, there is a risk of en
gine damage due to the high temperature difference.
For this reason:
S Do not fill with cold coolant.
Special tools
[1] Connecting piece M26x1,5 51.981310279

SS Filling with coolant

Operation
Fill the cooling system of the engine with a mixture of tap water and ethylene glycol antifreeze agent or an
ticorrosion agent.
Only use approved Fuels, Lubricants and Coolants (see Publication “Operating fuels, lubricants and
coolants for MAN diesel engines”).
1. Unscrew the screw cap (1).

2. Unscrew and remove the screw plug (2) with
the sealing ring on the drain valve (2) and (3).
3. Screw on connecting piece [1] with a hose on
the drain valve (2) and (3). Place a container
with sufficient capacity under the end of the
hose.
For coolant filling capacity, see “Technical Data”
page 68.
4. Slowly add coolant at the filler neck until the
coolant starts to escape at the drain valve (2)
and (3).
5. Unscrew the connecting piece [1] with the hose
from the drain valve (2) and (3) and screw on
the cap with the sealing washer.
6. Continue to add coolant slowly until it reaches
the lower edge of the filler neck.
7. Screw the screw cap (1) back on.
8. Check the entire cooling system for leaks, see
page 51.
9. Start the engine and drive to warm it up; when
the engine temperature has reached 82 °C,
continue driving for another 15 minutes.
12.Stop the engine and let it cool down to below
60 °C.
13.If necessary, top up the coolant by adding it at
the filler neck (1) and bleed the engine coolant
circuit by means of the drain valve (2) and (3).
With an incorrect mixture of anti-freeze and corrosion protection agent, lime scale and rust deposits may
build up in the engine coolant circuit and these may impair the cooling performance and the function of the
coolant pump.
In such cases it is necessary to clean the coolant circuit at appropriate intervals of time.

Operation

To check whether cooling system is free from leaks, an air pressure connection
and a pressure gauge must be attached at the threaded connection for the level sensor.
Cooling system must be pressurized with an air pressure of 1.0 bar with the engine at a standstill. After the
air supply has been disconnected, the applied preliminary pressure of 1.0 bar must be held for at least
30 minutes.
If this is not the case, the cause of the leak must be located and eliminated.
Leaks caused by the valves on the expansion tank can be eliminated by applying some grease to the
rubber seal.Filling Engine Oil
7.3.5 Check Engine Oil Level
NOTE!
Check the oil level when the engine is horizontal and only after at least 20 minutes have
passed since the engine was switched off.
1. Pull out oil dipstick (1).

2. Wipe oil dipstick with a clean, fibre-free cloth.
3.Reinsert the oil dipstick up to the stop.
4. Withdraw the dipstick and check oil level.
The oil level should be between both of the marks
on the dipstick and should never drop below the
lower mark.
5. Reinsert the oil dipstick (1) all the way.
If the oil level is too low, refill with new oil.
MAX
MIN

Operation
7.3.6 Top up with engine oil
IMPORTANT!
cants!
For this reason:
S Only use approved Fuels, Lubricants and Coolants (see Publication “Operating fuels,
lubricants and coolants for MAN diesel engines”).
IMPORTANT!
Component damage caused by
over filling!
Engine damage can occur if engine
oil is filled to above the max. mark
on the oil dipstick.
For this reason:
S Do not fill engine oil above the
max. mark on the oil dipstick
MAX
MIN
1. Remove cap (1).

2. Slowly fill engine oil into the filler opening.
The oil level should be between both marks on the
dipstick.
4. Check engine oil level.

Operation
7.4 Operation
7.4.1 Operation monitoring system
IMPORTANT!
Do not overload engine.
If faults occur, investigate and solve them immediately to prevent major damage from oc
curring!
The engine oil pressure is monitored during its operation.

If a fall in oil pressure is reported by the monitor, immediately shut down engine.
7.4.2 Stopping in the event of an emergency

An emergency-off button, for shutting down the system in an emergency, must be installed for each engine.

Operation

Maintenance and Care
8 Care and maintenance
WARNING!
Risk of injury caused by improperly performed maintenance!
Improper maintenance can case serious injuries or considerable property damage.
For this reason:
S Before carrying out maintenance work, carefully read the maintenance instruction.
S Carry out all maintenance steps in accordance with the information in the maintenance
instruction.
8.1 Maintenance instruction

An engine maintenance instruction is available as a supplement to this operating instruction.
It contains a maintenance plan as well as a description of all regular maintenance work.
8.1.1 Maintenance Schedule

The maintenance plan includes all maintenance work, which has to be carried out at intervals or on reach
ing a specified number of operating hours.
8.1.2 Maintenance work

The maintenance instruction contains a brief description of the maintenance work.
8.2 Repair instruction

The repair instruction contains a detailed description of all assembly and installation work on the engine.
This work must only be undertaken by specialists specifically trained for the repair work.

Maintenance and Care

Faults
9 Faults
The following chapter describes the possible faults which can occur and the work to correct them.
In the event of faults, which cannot be eliminated by the following instructions, contact the manufacturer of
the overall plant or MAN.
9.1 Prerequisite
chapter.
Personnel
S Engine faults may only be rectified by specially trained qualified personnel or by the manufacturer.

S Safety Shoes
S Safety Gloves
Ground rules
WARNING!
Risk of injury caused by improper rectification of faults!
Improper rectification of faults can case serious injuries or considerable property damage.
For this reason:
S Ensure that the engine cannot be started by unauthorised persons.
S Make sure work space is kept clean and orderly! Any unused parts or components lying
around are potential sources of accidents.

Faults
9.3 Fault table
Fault Possible cause Remedy

Engine does not start D Fuel tank empty
D Fuel valve shut off
D Air in fuel system
D Fuel lines leak, broken or clogged
D Fuel filter/air filter clogged
D Condensation in fuel D Drain water from fuel filter and
tank
D Air filter clogged
D Exhaust clogged
(exhaust back pressure too high)
D Electric circuit interrupted D Set main switch to "on"
D Replace faulty fuses
D Repair any loose, corroded and
broken wires and contacts
D Battery dead
D Starter/Solenoid switch defect D See further under "Starter"
D Injectors clogged
D Valves do not close or are stuck
D Crank assembly is externally blocked D Remove objects that interfere
with the movement of the fan,
power output, alternator, etc.
D Inner engine damage (piston seizure,
possibly caused by water in fuel)
Engine starts but does D Fuel filter clogged
not reach idle speed or D Fuel grade does not meet the specifica
stalls tions or is contaminated D See "Fluids and Lubricants...."
D Air filter clogged
Engine does not start D Engine shut off faulty
or poorly starts in war D Insufficient compression in cylinder or
med up condition more than 3-4 bar pressure difference
between the cylinders
Engine does not start D Fuel filter clogged with paraffin D Replace filter
or poorly starts in cold
condition
Rough idle with engine D Air in fuel system
warm, misfires D Fuel lines leak, broken or clogged
D Fuel filter clogged
D Lower idle speed is set too low
D Valve clearance not OK
D Injectors or injection lines leak
D Turbocharger faulty D Help from the manufacturer ser
vice
D Insufficient compression in cylinder or
more than 3-4 bar pressure difference
Engine speed fluctua D Not enough fuel in the tank
tions during operation D Air in fuel system
D Tachometer faulty
D Injectors faulty

Faults
Poor performance D Too much power is demanded from the

engine than it can produce
D Fuel filter/air filter clogged
D Fuel grade does not meet the regu D See "Fluids and Lubricants..."
lations
D Insufficient fuel supply D Fuel feed pump worn or faulty
D Oil level in oil pan too high D Check whether the guide tube is
correctly installed and the cor
rect oil dipstick is being used
D If coolant or fuel is discovered in
the engine oil, check cylinder
head gasket, cylinder liner gas
ket and piston rings
D Exhaust pipe blocked
D Air intake pipe leaks
D Turbocharger leaks or has a fault
D Insufficient compression in cylinder or
more than 3-4 bar pressure difference
D Rated speed incorrectly set
Coolant temperature D Coolant level too low
too high, loss of coolant D Air in coolant circuit
D Radiator very dirty, fins clogged
D Locking cap with operating valves on
expansion reservoir/radiator is faulty or
leaks
D Temperature display faulty
D Coolant pump leaks, defective (bearing
damage)
D Thermostat faulty, does not open
D Coolant lines leak, clogged or twisted
Lube-oil pressure too D Oil level in oil pan too low
low D Engine temperature to high
D Oil filter clogged
D Oil pressure indicator faulty
D Selected oil viscosity is inappropriate for D See "Fluids and Lubricants..."
ambient temperature (too thin)
D Oil in oil pan is too thin (contains con
densation or fuel)
D Bearing heavily worn
D Oil pump gears heavily worn
D Safety valve in oil circuit faulty (does not
close, spring is worn or broken)
Lube-oil pressure too D Engine cold
high D Selected oil viscosity is inappropriate for D See "Fluids and Lubricants..."
ambient temperature (too thick)
D Oil pressure indicator faulty
D Safety valve in oil circuit faulty (does not
open)
D Oil lines/oil ducts clogged

Faults
Lube-oil consumption D Lube-oil quality does not meet the regu D See "Fluids and Lubricants..."
too high lations
D Oil level in oil pan too high D Check whether the guide tube is
correctly installed and the cor
rect oil dipstick is being used
D If coolant or fuel is discovered in
the engine oil, check cylinder
head gasket, cylinder liner gas
ket and piston rings
D Leaks in lube-oil circuit especially at the
turbocharger and oil cooler
D Piston rings heavily worn
D Valve stems heavily worn, bent
Fuel consumption too D Fuel grade does not meet the specifica D See "Fluids and Lubricants..."
high tions
D Fuel loss due to leaks in system
D Valve seat leaks
Black smoke accom D Air filter clogged
panied by a fall in D Air intake duct leading to turbocharger
power leaks
D Exhaust clogged (exhaust back
pressure too high)
D Turbocharger faulty D Help from the manufacturer ser
vice
D Intercooler leaks, faulty
D Injectors faulty, carbonised
Blue smoke D Engine/coolant/intake air still too cold
D Lube oil penetrates into combustion
chamber (pistons/piston rings worn or
piston rings broken)
D Valve stem/guide worn
D Overpressure in crankcase (crankcase
ventilation system clogged)
White smoke D Engine/coolant/intake air still too cold
D Fuel tank empty
D Fuel lines leak, broken or clogged
D Coolant penetrates into combustion
chamber (cylinder head/gasket leaks)
D Fuel filter clogged
D Fuel grade does not meet the specifica D See "Fluids and Lubricants..."
tions
D Injectors faulty

Faults
Engine knocking D Engine not at correct operating tempe D Let engine warm to operating
rature temperature before running at
full load
D Valve clearance not OK D Check thermostat
D Valves stick
D Piston pin or crankshaft bearing loose
D Piston ring broken
Engine too "loud" D Intake or exhaust pipe leaks
D Timing gears worn, gear backlash too
large
D Valve clearance too large
D Turbine and compressor impeller in tur D Help from the manufacturer ser
bocharger dirty (rough running, out of vice
balance)
D Poly-V-belt slips
Starter Obtain assistance only from ve
hicle electrician or manufactur
er's service department/re
D Pinion gear does not D Battery has insufficient charge presentative
turn or turns slowly D Terminal is loose, oxidised, poor
connection to ground
D Starter terminals or carbon brushes
have a ground fault
D Carbon brushes stick or have poor con
tact
D Pinion gear does not D Pinion or starter ring is dirty or damaged
engage
D Pinion gear D Solenoid switch faulty
engages, but stops D Overrunning clutch slips
turning
D Pinion gear conti D Starter switch faulty
nues to turn after D Solenoid switch faulty
starter switch is re
leased
D Pinion gear does not D Starter defect D Immediately shut down engine
disengage after en
gine starts

Faults

Decommissioning and Recommissioning
10 Decommissioning and Recommissioning
10.1 Prerequisite
chapter.

S Safety Shoes
S Safety Gloves
Personnel
S Decommissioning and recommissioning of the engine may only be made be trained and qualified per
sonnel.
Ground Rules
WARNING!
Risk of injury caused by improper work.
Improper work can case serious injuries or considerable property damage.
For this reason:
S Ensure that the engine cannot be started be unauthorised persons.
S Perform all work steps in accordance with the instructions in these Operating Instructions.
S Make sure work space is kept clean and orderly! Any unused parts or components lying
around are potential sources of accidents.

10.3 Temporary decommissioning of an engine

Temporary anticorrosion protection according to MAN works norm M 3069 is required for engines which are
to be put out of service depending on the duration.
The works norm can be obtained from our After-Sales Service department Nuremberg works.
NOTE!
A proper and careful recommissioning of new or operated engines has a great impact on
the operating safety and remaining life of the engines.
In general the goal is to preserve the decommissioned engines or new engines (after the
factory tests).
If the engine was not preserved before decommissioning, there is a risk that the cylinder
liners, piston rings and valves will corrode, especially when the intake and exhaust opening
are not closed off or when the engine is stored in the open.
Foreign matter, rain water and similar conditions require a complete disassembly of the en
gine.

10.4 Recommissioning of decommissioned engines
10.4.1 Commissioning of preserved engines in accordance with MAN-Werknorm

M 3069
1. Remove external preservation. Never use a high pressure cleaner for this.
2. Remove caps from intake and exhaust openings.
3. Check cooling system; add antifreeze according to the Fluids and Lubricants list (see “Fluids and Lubri
cants ..."); check concentration and correct.
4. Check engine oil level and add fresh approved engine oil if necessary.
5. Fill fuel, bleed system.
Check the operation of the monitoring and emergency shut off equipment.
6. Check condition and proper installation of elastic fasteners, such as V-belts, coolant hoses and charge
air hoses. Retighten if necessary.
7. Rotate engine with fuel injection turned off until oil pressure builds up. Operate starter no more than
5 seconds for this.
8. Open fuel injection and start engine. After engine is running, operate engine above idle speed to avoid
insufficient lubrication of the cylinder liners.
9. Check engine for leaks, unusual noises and observe the oil pressure and all temperatures. Increase en
gine speed in steps.
10.After a max. of 25 operating hours, drain preservation oil from engine and change oil filter; fill engine
with fresh approved engine oil.
10.4.2 Commissioning of non-preserved engines

In addition to the work steps for a preserved engine, the commissioning of a non-preserved engine requires
the following extra work depending on the possible non use damage.
1. Check combustion chambers with an endoscope, to do this, remove/install injectors.
Check valve for easy movement; check valve clearance and adjust if necessary.
Replace any damaged/corroded parts.
2. Drain old oil from engine and change oil filter. Fill engine with fresh approved engine oil.
3. Check cooling system for corrosion; check coolant for proper concentration; if in doubt, change coolant.
Before adding new coolant , clean coolant chambers and remove/install coolant pump and thermostat if
necessary; replace the slide ring seal of the coolant pump and thermostat elements; pressure test coo
ling system.
4. Check clean air system, air filter and turbocharger for dirt and corrosion. Clean or repair if necessary.
5. Clean fuel system and drain old fuel if necessary. Clean/check/replace filter.


Technical Data
11 Technical Data
11.1 Dimensions and weight
11.1.1 With cooling system (MAN scope of delivery)

Specification Value Unit
Weight (dry) 2477 kg
A 2619 mm
B 1561 mm
C 1916 mm
11.1.2 With Duralite air filter (without cooling system)

Specification Value Unit
Weight (dry) 2155 kg
A 2084 mm
B 1215 mm
C 1567 mm
11.2 Requirements of the installation site, space required

Observe the information in the Assembly Instructions.

Technical Data
11.3 Engine data

11.3.1 D2862 LE221
Engine model D2862 LE221
Design V 90°
Operating Principle 4-Stroke - Diesel with Supercharging and Intercooling
Combustion system Direct injection
Charging Exhaust turbocharger with Intercooling
Number of cylinders 12
Bore 128 mm
Stroke 157 mm
Displacement 24,243 cm3
Compression ratio 17 : 1
Rating
D2862 LE221 700 kW / 951 PS at 1500 rpm
836 kW / 1137 PS at 1800 rpm
Max. torque
D2862 LE221 4457 Nm at 1500 rpm
4435 Nm at 1800 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Valve clearance (cold engine)
Intake 0.50 mm
Exhaust 0.80 mm
Valve timing
Intake opens 24° before TDC
Intake closes 36° after UT
Exhaust opens 63° before BDC
Exhaust closes 27° after TDC
Fuel system
High-pressure pump Bosch CP 3.4
Injection system Common Rail
Governor Electronically controlled diesel injection
(EDC) - Type EDC 7 C32
Injectors 8 hole injector nozzle
Engine lubrication Force feed lubrication
Oil change quantity (with filter) 84 l
Oil filter 2 oil modules, each with 2 oil coolers and an oil separator
Engine cooling system Liquid cooling
Coolant temperature 80-90 °C, 95 °C permissible temporarily
Coolant capacity Depending on the cooling system installed, specified by cooling
system manufacturer
Electrical equipment
Starter 24 V; 7.0 kW
Alternator 28 V; 120 A

Technical Data
11.3.2 D2862 LE223

Design V 90°
Bore 128 mm
Stroke 157 mm
Rating
D2862 LE223 880 kW / 1196 PS at 1500 rpm
1117 kW / 1518 PS at 1800 rpm
Max. torque
D2862 LE223 5603 Nm at 1500 rpm
5926 Nm at 1800 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Intake 0.50 mm
Exhaust 0.80 mm
Valve timing
Fuel system
system manufacturer

Technical Data
11.3.3 D2862 LE231

Design V 90°
Bore 128 mm
Stroke 157 mm
Rating
D2862 LE231 800 kW / 1188 PS at 1500 rpm
836 kW / 1137 PS at 1800 rpm
Max. torque
D2862 LE231 5603 Nm at 1500 rpm
4435 Nm at 1800 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Intake 0.50 mm
Exhaust 0.80 mm
Valve timing
Fuel system
system manufacturer

Technical Data
11.3.4 D2862 LE233

Design V 90°
Bore 128 mm
Stroke 157 mm
Displacement 24 243 cm3
Rating
D2862 LE233 880 kW / 1197 PS at 1500 rpm
920 kW / 1251 PS at 1800 rpm
Max. torque
D2862 LE233 5602 Nm at 1500 rpm
4881 Nm at 1800 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Intake 0.50 mm
Exhaust 0.80 mm
Valve timing
Fuel system
system manufacturer

Technical Data
11.4 Coordinates of the center of gravity

The coordinates of the center of gravity and the mass moments of inertia for the engine are determined
using methods from experimental modal analysis.
Explanation of the measured quantities

m: Dry mass of the engine without oil [kg]
xs : Center of gravity of the engine along the major axis (measured from the rear edge of the fly
wheel housing [mm]
ys : Center of gravity of the engine along the minor axis [mm]
zs : Center of gravity of the engine along the vertical axis [mm]
(measured from the crankshaft axis looking at the flxwheel housing
Origin of the coordinate system in the crankshaft axis/flywheel housing near edge.
lzz: Mass moment of inertia in the center of gravity of the engine when rotating about the vertical
axis z [kgm2]
lyy: Mass moment of inertia in the center of gravity otf the engine when rotating about the minor axis
y [kgm2]
lxx: Mass moment of inertia in the center of gravity of the engine when rotating about the major axis
y [kgm2]
Engine without cooling system

Engine mass Coordinates of the center of gravity Mass moment of inertia [kgm2] um
m [kg] [mm]
Major axis Minor axis Vertical
axis
xs ys zs lxx lyy lzz
2155 -696 -1 352 313 469 360
Engine with cooling system

Total mass Coordinates of the center of gravity [mm]
mG [kg] xs ys zs
2155 -857 -2 366
Cooling sys Coordinates of the center of gravity [mm]
tem mass mK
[kg] xs ys zs
290 -696 -2 373

Massenträgheitsmoment [kgm2] um
Engine mass Coordinates of the center of gravity [mm] Längsachs Querachse Hochachse
m [kg] e
xs ys zs lxx lyy lzz
2187 -694 -2 365 337 476 361

Technical Data

Technical Data
z axis
y axis

Technical Data
z axis
x axis

Technical Data

Indices
12 Appendices

Indices
12.1 Abbreviations
A . . . . . . . . . Amps MAX . . . . . . Maximum

Ah . . . . . . . . Amp hours MFR . . . . . . MotorFührungsRechner (engine ma
nagement computer)
bzw. . . . . . . Respectively
min . . . . . . . Minutes
C . . . . . . . . . Celsius
MIN . . . . . . Minimum
CAN . . . . . . Network for control units, data bus
system in vehicle (Controller Area mm . . . . . . . Millimetre
Network)
NC . . . . . . . Not Connected
cm3 . . . . . . Cubic centimetre
Nm . . . . . . . Newton meter
EDC . . . . . . Electronically controlled diesel injec
Occ . . . . . . Occurrence Counter
tion (Electronic Diesel Control)
TDC . . . . . . Top dead centre
EDR . . . . . . EnDabRegler (final speed governor)
Pot . . . . . . . Potentiometer
evtl. . . . . . . Possibly
Prio . . . . . . Priority
Fa. . . . . . . . Company
PWG . . . . . PedalWertGeber (pedal value trans
FMI . . . . . . . Fault Mode Identification
mitter)
ggf. . . . . . . . If necessary
RTC . . . . . . RealTimeClock
GND . . . . . . Ground
SPN . . . . . . Suspect Parameter Number
h . . . . . . . . . Hours
UBat ....... Battery voltage
Chap. . . . . . Chapter
UDS . . . . . . Unified Diagnostic Services
kg . . . . . . . . Kilogram
usw. . . . . . . and so on (etc.)
Tl. . . . . . . . . Terminal
BDC . . . . . . Bottom dead centre
KSM . . . . . . Kundenspezifisches SteuerModul (cu
V . . . . . . . . . Volt
stomer specific control module)
W . . . . . . . . Watt
kW . . . . . . . Kilowatt
X2 . . . . . . . . Customer connector X2 on wiring dia
LCD . . . . . . Liquid Crystal Display
gram
LED . . . . . . Light Emitting Diode
e.g. . . . . . . . For example
LLR . . . . . . LeerLaufRegler (idle speed governor)
ZDR . . . . . . Zwischendrehzahlegelung (interme
LSB . . . . . . LastSignificantBit diate speed regulation)
m . . . . . . . . Metre zul. . . . . . . . Permitted (per.)
MANcats . MANcomputer assisted testing and > . . . . . . . . . Greater than
diagnostic system
< . . . . . . . . . Less than
. . . . . . . . . See
rpm . . . . . . . Revolutions per minute

Indices
12.2 Technical terms
CAN, developed at the start of the 1980's by

Bosch, in particular for the fast exchange of serial
data between electronic control units in vehicles .
Using CAN, each message to be transferred is
uniquely identified by means of a message identi
fier. In contrast to station addressing, here there is
no control unit and instead the message is self-ad
dressed. By this means a message is basically
available for each CAN-bus-station to receive. The
acceptance of a message
depends solely on the decision of the control unit.
Thus it is possible, that a message can be re
ceived from one, several, or all control units for
further processing.
CR means Common Rail. While conventional in

jection diesel engines produce the fuel pressure for
each injection cycle anew, in the common rail sys
tem the fuel pressure is produced independently
from the injection sequence and is continuously
available in the fuel line. Generation of fuel
pressure and the injection process take place in
dependently from each other. This technique ena
bles an on-demand fuel injection, which has a fa
vourable effect on fuel consumption and exhaust
emissions.
EDC, Electronic Diesel Control is an electronically

controlled diesel injection system. This positively
affects the fuel consumption, economy, exhaust
and noise behaviour.
MFR, Engine command computer; takes over the

processing of engine electronic signals.

Indices
12.3 List of key words

A I
Alterations and modifications . . . . . . . . . . . . . . . . . 4 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . 27
Applicable documentation . . . . . . . . . . . . . . . . . . . 9 Information on the operating instructions . . . . . . . 7
Installation - Engine . . . . . . . . . . . . . . . . . . . . . . . . 42
B Installation and Commissioning . . . . . . . . . . . . . . 41
Behaviour in dangerous situations . . . . . . . . . . . 23 Intake and Exhaust System . . . . . . . . . . . . . . . . . 29
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Care and maintenance . . . . . . . . . . . . . . . . . . . . . 55
Check coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 M
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . 51 Maintenance instruction . . . . . . . . . . . . . . . . . . . . 55
Check fuel contents and top up . . . . . . . . . . . . . . 48 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 55
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . 55
Construction and function . . . . . . . . . . . . . . . . . . 29
Content of the operating instruction . . . . . . . . . . 14 O
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operation monitoring system . . . . . . . . . . . . . . . . 53
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . 11
P
D Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Data on the engine type plate . . . . . . . . . . . . . . . 43 Personal protection equipment . . . . . . . . . . . . . . 16
Decommissioning and Recommissioning . . . . . 63 Personnel requirements . . . . . . . . . . . . . . . . . . . . 15
Dichtheitsprüfung gesamtes Kühlsystem . . . . . . 51 Preparation before operation . . . . . . . . . . . . . . . . 48
Dimensions and weight . . . . . . . . . . . . . . . . . . . . . 67 Protection of the environment . . . . . . . . . . . . . . . 25
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
R
E Recommissioning of decommissioned engines 65
Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Repair instruction . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 29 Requirements of the installation site,
Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 29 space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Responsibility of the operator . . . . . . . . . . . . . . . 14
Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Restriction of liability . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
S
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . 8
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . 22, 42
F Signs and notices . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Special dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 46, 51 Stopping in the event of an emergency . . . . . . . 53
Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . 45 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Filling with diesel fuel . . . . . . . . . . . . . . . . . . . . . . 44
Fuel System, General . . . . . . . . . . . . . . . . . . . . . . 29
H
Handling and operation . . . . . . . . . . . . . . . . . . . . . 47

Indices
T W
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . 11
Temporary decommissioning . . . . . . . . . . . . . . . . 64
Top up with coolant . . . . . . . . . . . . . . . . . . . . . . . . 50
Top up with engine oil . . . . . . . . . . . . . . . . . . . . . . 52
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Transport inspection . . . . . . . . . . . . . . . . . . . . . . . 37
Transport, packaging and storage . . . . . . . . . . . 35

Notes
13 Notes
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MAN Truck & Bus SE
Vogelweiherstraße 33
90441 Nuremberg
Germany
man-engines@man.eu
www.man-engines.com

Operating Instruction: MAN Industrial Diesel Engines D2862 LE221/223/231/233

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Operating Instruction: MAN Industrial Diesel Engines D2862 LE221/223/231/233

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Operating Instruction

MAN Industrial Diesel Engines

MAN Industrial Diesel Engines

51.99587-5144 “Original instruction”

Technical status: 09.2017

Carefully read the Operating Instructions before starting any work!

2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Carefully read the Operating Instructions before starting any work!

4 Construction and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Transport, packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Carefully read the Operating Instructions before starting any work!

7 Handling and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8 Care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

10 Decommissioning and Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Carefully read the Operating Instructions before starting any work!

Carefully read the Operating Instructions before starting any work!

1.1 Information on the operating instructions

1.1.1 Publications, which relate to the operating instructions

1.1.2 Supplementary documentation for the engine

For the operator, maintenance and service personnel

For the service personnel

Carefully read the Operating Instructions before starting any work!

1.2 Explanation of symbols

Tips and Recommendations

Carefully read the Operating Instructions before starting any work!

1.3 Restriction of liability

1.5 Applicable documentation

Carefully read the Operating Instructions before starting any work!

1.6 Spare parts

Order spare parts through an authorised dealer or directly from MAN.

Carefully read the Operating Instructions before starting any work!

1.8 Warranty conditions

1.9 Customer service

Carefully read the Operating Instructions before starting any work!

Carefully read the Operating Instructions before starting any work!

2 General Safety Instructions

2.1 Intended use

Carefully read the Operating Instructions before starting any work!

2.2 Content of the operating instruction

2.3 Alterations and modifications on the engine

2.4 Responsibility of the operator

Carefully read the Operating Instructions before starting any work!

2.5 Personnel requirements

2.5.2 Unauthorised persons

Carefully read the Operating Instructions before starting any work!

2.6 Personal protection equipment

To be worn when performing specific types of work

Carefully read the Operating Instructions before starting any work!

2.7 Special dangers

Carefully read the Operating Instructions before starting any work!

Highly Flammable Substances - Diesel Fuel, Oils and Grease

Coolants - Antifreeze, Anticorrosion Agents

Hot Fluids and Lubricants

Carefully read the Operating Instructions before starting any work!

Sharp Edges and Corners

Dirt and Objects

Carefully read the Operating Instructions before starting any work!

Working on the Common Rail System

Carefully read the Operating Instructions before starting any work!

Carefully read the Operating Instructions before starting any work!

2.8 Safety devices

In all communications please always state the en