Maintenance Manual: MAN Industrial Diesel Engines D2862 LE221/223/231/233

Maintenance Manual
MAN Industrial Diesel Engines

D2862 LE221/223/231/233
MAN Engines
Maintenance Instructions
MAN Industrial Diesel Engines
D2862 LE221 / LE223 / LE231 / LE233
51.99597-8022 “Translation of the original maintenance instructions”

Version 05
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 AG assumes no liability for any
damages arising from noncompliance 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.
 2018
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1932
Email: Engine-Documentation@man.eu
Internet: www.engines.man.eu
Technical status: 02.2018

51.99597-8022
Carefully read the Maintenance 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.
MAN Industrial Diesel Engines D2862 LE221/D2862 LE223
Content
Information and Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Applicability of the assembly instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Important additional information regarding the assembly instruction . . . . . . . . . . . . . 5
1.1.2 Supplementary information with reference to the assembly instruction . . . . . . . . . . . 5
1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Restriction of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Applicable documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Content of the assembly instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Modifications and changes to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Responsibility of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.1 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.2 Unauthorised persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.3 Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Personal protection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Special dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.8.1 Emergency-Stop device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.8.2 Belt guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.8.3 Fan cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.8.4 Heat protection covers for exhaust pipes and turbine housings . . . . . . . . . . . . . . . . . 20
2.9 Behaviour in a dangerous situation and in the event of accidents . . . . . . . . . . . . . . . . . . . . 21
2.10 Signs and notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.11 Protection of the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.1 Explanation of Engine No./Engine No. (Engine identification number) . . . . . . . . . . . . . . . . . 26
3.2 Explanation of type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4 Transport, packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Carefully read the Assembly Instructions before starting any work!

and the safety instructions in each of the chapters. 3
Content
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3 Interfaces between engine and plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3.1 Installation drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3.2 Bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4 Completion of the engine and assembly of the equipment set . . . . . . . . . . . . . . . . . . . . . . . 36
5.4.1 Flange mounting of the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.4.2 Check crankshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.5 Installation on the equipment set frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5.1 Bolting the engine to the base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.6 Connect cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6.1 Connect coolant lines for the engine cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6.2 Connect expansion tank for engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6.3 Install cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6.4 Connection parts 51.06100-6224 for fan cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.7 Connect fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.8 Connect air lines for the combustion air (Intercooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.9 Install exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.9.1 Install exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.9.2 Install Exhaust gas compensators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.10 Connect electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.10.1 Connect starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.10.3 Connect wiring harness plug connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.10.4 connect MFR control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.11 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.11.1 Install belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.11.2 Install fan cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.11.3 Install heat protection cover on exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 Fill with Fuels, Lubricants and Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1.1 Fill with engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.1.2 Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1.3 Fill with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2 Commissioning the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7 Installation drawing for the engines D2862 LE221/223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.1 Version with cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2 Version with Duralite air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Carefully read the Assembly Instructions before starting any work!

Foreword
1 Foreword
1.1 Information on the maintenance instruction

This maintenance instruction contains a maintenance plan, important information on the maintenance and
proof of maintenance. The prerequisite for safe working is adherence to all safety information 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.
The maintenance plan provides information on the maintenance intervals and defines the type of mainte
nance that has to be undertaken. All maintenance work is to be acknowledged as having been carried out
on the associated proof of maintenance in the appendix to this instruction.
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 are thus suitable for use in our en
gines.
1.1.1 Supplementary information relating to the maintenance instruction

The following instructions are available for the engine to supplement this maintenance instruction:
- Operating instruction (included in the scope of delivery)
- Operating fuels, lubricants and fluids for MAN diesel engines (included in the scope of delivery)
For the service personnel

- Repair Instructions

Foreword
1.2 Key to 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.
[1] This symbol in the text indicates the position of a special tool.

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
This maintenance instruction is to be treated as confidential. It is intended exclusively for the use of per
sons working on the engine.
The onward transmission of this maintenance instruction to a third party, without the express written
permission of MAN is forbidden.
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 Relevant publications

Supplier components are installed in the engine (e.g. injection system). For these bought-in parts the risk
assessments of the respective suppliers are to be carried out.
The compliance of the construction with the respective applicable European and national regulations is de
clared by the respective component supplier.

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 are thus suitable for use in our en
gines.
Spare parts and accessories must either be original MAN parts or parts that are expressly approved by
MAN. For these parts the reliability, safety and for engines have been specifically established. For other
products, despite on-going market observations, we cannot provide an assessment and therefore cannot
vouch for them.
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!
In all communications and enquiries, please state engine type, engine number and the
order/contract number, see operating instruction.
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.
The non-adherence to this maintenance instruction and any appended supplier instructions will result in 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!
In all communications and enquiries, please state engine type, engine number and the
order/contract number, see operating instruction
Information about contact persons can always be called up by telephone, fax, e-mail 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.
The failure to adhere to the handling and safety instructions detailed in this maintenance instruction can
lead to considerable danger.
2.1 Intended Use

The engine is built exclusively for emergency power operation (LTP) and peak load operation (PRP).
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 must only be used outside hazardous (Ex) zones.

2.2 Content of the maintenance instruction

Every person, who is authorised to carry out work on or with the engine, must have read and understood
the maintenance instruction before commencing work on the engine. This also applies, when the person
concerned has already undertaken work on the same or similar engines or has been trained by MAN.
Knowledge of the maintenance instruction is thus obligatory.
2.3 Modifications and Conversions to the Engine

In order to avoid hazards and to ensure optimum performance, no modifications or conversions to the en
gine may be made which are not expressly approved by MAN.
If changes are made without the written consent of MAN, the guarantee or warranty obligation for MAN is
not longer valid for damage and defects, which are based on these unauthorised changes. Furthermore
MAN assumes no liability for any damage caused as a result of unauthorised changes.
2.4 Responsibility of the Operator

The operator of the motor is subject to the statutory requirements for workplace safety.
In addition to the Safety Instructions in these Operating Instructions, the safety regulations, accident pre
vention regulations and environmental protection regulations valid for the application area of this engine
must also be observed.
In particular:
S The operator must be knowledgeable about the valid occupational health and safety regulations and be
able to assess, in a risk analysis, the dangers that are present in the specific working conditions at the
operating site of the engine. He must then implement these safety regulations in the form of operating
instructions for the operation of the engine.
S During the entire period of operation of the engine the operator must check whether the operating in
structions he created meet the most current standards for regulations and revise them if necessary.
S The operator must clearly define and regulate the responsibilities for installation, operation, maintenance
and cleaning of the product.
S The operator must ensure that all staff who deal with the engine have read and understood the 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 This maintenance instruction must be kept in the immediate vicinity of the engine and accessible at all
times to persons working on the engine.
The operator is responsible for ensuring that the engine is always operated in perfect working condition and
working order.
In particular:
S Maintenance work such as that described in the Maintenance Instructions are to be completely per
formed within the prescribed time intervals or are to be performed by a MAN service workshop/MAN
contract partner.
S The operator must have all safety equipment checked regularly for function and integrity.
S The instructions in the Operating Instructions are to be followed completely and fully!

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.
In the maintenance instruction the following qualifications are named for various areas of activity:
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 regular basis and this should be documented in a log to keep better track
of who and when.

2.6 Personal Protective 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 Specific Dangers

The following section describes residual risks which have been identified.
S Observe the safety instructions listed here and the warnings in the other chapters of these instructions
in order to reduce health hazards and avoid dangerous situations.
Electrical Current
DANGER!
Risk of death caused by electrical current!
There is a risk of death when coming into contact with parts conducting electrical currents.
Damaged insulation or components can be life threatening.
For this reason:
S If the insulation is damaged, immediately switch off the power supply and get the 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 plants
WARNING!
Risk of injury through engines in the vicinity!
In the event of damage to engines, persons in the operating area are endangered.
For this reason:
S The time spent in the operating area should be limited to that absolutely necessary.
S Set up separating protective devices for running engines.
S Remaining in the operating area is only permitted with the engines running at low load
conditions.

Exhaust gases
WARNING!
Risk to health from exhaust gases!
Faulty sealing in the exhaust system can result in dangerous exhaust gases being present
in the machine room.
For this reason:
S Provide adequate ventilation.
S Machines with unsealed exhaust systems must be shutdown 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 and this can lead to serious injury 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 depressurised. 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 Equipment
Before the engine is commissioned, the operator must provide 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 device

Connect the emergency-off 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 alternator and the fan must be provided with protective covers in order to exclude
dangerous situations for persons and material assets.
2.8.3 Fan protective cover

The fan is to be provided with a protective cover in order to exclude dangerous situations for persons and
material assets
2.8.4 Heat protection for exhaust pipe and turbine housing

Exhaust pipes and turbine housings are always to be provided with suitable heat protection covers in order
to exclude dangerous situations for persons and material assets.

2.9 Conduct in Dangerous Situations and When Accidents Occur
Preventative Measures
S Always be prepared for an accident!
S Keep first aid equipment (first aid kit, blankets, etc.) and fire extinguishers at hand.
S Check first aid equipment and fire extinguishers regularly for completeness and proper operation.
S Familiarise the personnel with the emergency, first aid and rescue equipment.
S Instruct the personnel on safety on a regular basis.
S Always keep access lanes for rescue vehicles free of any obstructions.
In the case of an accident: Act accordingly

S Remain calm.
S Immediately shut down engine using the emergency-off button.
S Start first aid measures.
S Alert rescue services and/or fire department.
S Move people out of the danger zone.
S Clear access lanes for rescue vehicles.
S Inform the person in charge.
CAUTION!
Accidents despite preventative measures
If an accident occurs, e.g. from one of the listed points below, despite all of the preventative
measures, contact a physician immediately.
S Contact with caustic acids.
S Penetration of fuel into the skin.
S Scalding by hot oil or coolant.
S Antifreeze sprayed into the eyes, etc..

2.10 Signs
The following symbols should be installed in the immediate vicinity of the hazard area.
WARNING!
Risk of injury caused by illegible symbols!
Stickers and symbols can become dirty or made otherwise illegible in the course of time!
For this reason:
S Always keep the safety, warning and operational signs in good legible condition.
S Clean or replace illegible safety, warning and operational signs.
Electric Voltage
Rooms marked with this symbol may only be accessed by qualified electricians.
Unauthorised persons may not enter these rooms.
Hot Surfaces
Hot surfaces such as hot engines and hot fluids may not always be recognisable. Do not
touch these surfaces without protective gloves.

2.11 Environmental Protection
CAUTION!
Environmental hazard caused by incorrect handling!
Incorrect handling of environmentally hazardous substances, especially when incorrectly
disposed of, can cause considerable damage to the environment.
For this reason:
S Always heed the information below.
S If environmentally hazardous substances are accidentally released into the environment,
immediately take suitable measures to minimise this. If in doubt, inform the responsible
local authorities.
The following environmentally hazardous substances are used:
Lubricants
Lubricants such as grease and oils contain poisons and environmentally hazardous substances. They must
not be allowed to be released into the environment. Disposal must be performed by a qualified disposal
company.
Diesel Fuel
Diesel fuel contains poisons and environmentally hazardous substances. They must not be allowed to be
released into the environment. Disposal must be performed by a qualified disposal company
Coolant
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.


Maintenance schedule
3 Maintenance schedule
Maintenance work is to be performed either after a certain number of operating hours has been reached or
at least once per year.
3.1 Maintenance according to Operating Hours

The Maintenance Schedule according to Operating Hours contains the scope and type of maintenance
work to be done for each number of operating hours. The maintenance work is listed according to priorities
such as “Cleaning Engine and Visual Inspections”. These are grouped into work groups are marked as M2,
M3, etc.
3.2 Daily Maintenance

Maintenance to be performed on a daily basis is marked with M1.
3.3 Maintenance according to Time Intervals

If the number of operating hours is not reached within one year then the Maintenance Schedule according
to Time Intervals is used instead. The scope and types of maintenance work are also marked with M2, M3,
M4, etc.
In addition to this, the work listed in scope “A” is to be performed every 4 years, irrespective of the number
of operating hours reached.
3.4 Performing Maintenance Work

All maintenance work, except for checking operation and visual checks, are described in chapter “Mainte
nance” starting on page 29.
IMPORTANT!
Incorrect or incomplete maintenance work can lead to major damage to the engine.
For this reason:
S Maintenance work may only be performed by trained and qualified personnel.
IMPORTANT!
Incorrect or incomplete maintenance work renders the liability for material defects
null and void.
For this reason:
S Have the maintenance fully undertaken and at the prescribed intervals by the MAN-Ser
vice-Workshop/MAN contractual partner.
3.5 Operating fluids and lubricants
NOTE!
For information on the fluids and lubricants see publication “Fuels, Lubricants and Coolants
for MAN Diesel Engines".
Approved products can be found on the Internet at:
https://ws-public.man-mn.com/portal/irj/asp

3.6 Maintenance plan on the basis of engine operating hours

Scope of maintenance operations
according to operating hours M2 M3 M4 M5 M6
20-50 x x
or after initial operation
500 x x x x
1000 x x x x x
1500 x x x x
2000 x x x x x
2500 x x x x
3000 x x x x x
3500 x x x x
4000 x x x x x
4500 x x x x
5000 x x x x x
5500 x x x x
6000 x x x x x
6500 x x x x
7000 x x x x x
7500 x x x x
8000 x x x x x
8500 x x x x
9000 x x x x x
9500 x x x x
10000 x x x x x
3.7 Maintenance Schedule according to Time Intervals

Scope of maintenance operations
According to time intervals M1 M2 M3 M4 M5 A
Daily x
Yearly x x x x
After every 4 years x

3.8 Scope of maintenance operations
M1 Daily Maintenance Work M3 Maintenance of filters

S Clean engine externally of dust and S Clean fuel pre-filter
dirt S Drain water from additional fuel filter1)
S Check engine exterior for oil‐ and S Air filter
coolant leaks M4 Changing engine oil and oil filter
S Check coolant level and oil level elements
S Service air filter S Engine oil
S Drain water from additional fuel filter S Engine oil filter cartridges
M2 Cleaning Engine and Visual Inspec S Fuel filter insert1)
tions S Fuelprefiltercartridge1)
S Clean engine externally of dust and M5 Check/Set
dirt S Valve clearance
S Check engine exterior for oil‐ and M6 Create fault diagnosis
coolant leaks S Read out diagnosis system memory
S Check coolant level from EDC and MFR
S Check concentration of antifreeze‐ / S Perform compression test and run-up
corrosion-protection agent test
S Check coolant hoses for condition S Visually inspect engine wiring har
and sealing ness for damage; do not to open any
S Check fuel lines for leaks connections
S Removable fasteners (screws/bolts,
A Change
hose clamps, pipe connections) and
S Coolant
tighten if necessary S All hoses for coolant
S Check condition of belts S Both locking caps on the expansion
S Check operation of instruments tank
S Check engine‐ alarms
1) Change filters earlier if they have heavy fuel soiling or high water contents.
The above mentioned maintenance work (M2 to M5) is to be performed by trained and qualified personnel
at the respective number of operating hours or at least once per year.
NOTE!
The maintenance schedule also contains work that is not listed in these Maintenance In
structions in the Maintenance Work chapter starting on page 29. These are listed in the Re
pair Instructions for this engine. This work may only be performed by specially trained quali
fied personnel.


Maintenance Work
4 Notes on the maintenance work
4.1 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 Safety Shoes
S Safety Gloves
4.2 Safety instructions
Personnel
S The maintenance work described in the maintenance instruction must only be undertaken by trained
specialist personnel.
Ground Rules
WARNING!
Risk of injury caused by improperly performed maintenance!
Improper maintenance 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 maintenance steps in accordance with the instructions in these Maintenance
Instructions.
S Ensure adequate work space before starting any work.
S Make sure work space is kept clean and orderly! Any unused parts or components lying
around are potential sources of accidents.
WARNING!
Risk of injury caused by maintenance work!
Before performing any maintenance work the engine must be set into the maintenance po
sition if nothing else is explicitly stated.
For this reason:
S The engine must be shut down.
S The engine must have cooled off.
S The battery main switch must be switched off and the ignition key removed.

Maintenance Work
IMPORTANT!
Termination of liability for material defects by use of non-approved fluids and lubri
cants!
Liability for 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).
NOTE!
Coolant
S Antifreeze and mixtures of antifreeze and water are to be handled as special wastes.
When disposing of used coolant observe the regulations of the local authorities.
Engine Oil
S Make absolutely sure that no oil gets into the sewage system or soaks into the ground
− Risk of contaminating drinking water!
Carefully collect used oil and properly recycle.
When handling used oil, observe the safety measures to protect your health.
Filter Elements
S Filter elements such as for oil and fuel must be handled as special waste and properly
disposed of. Observe the regulations of the local authorities.
Batteries
S Used batteries contain hazardous substances. Batteries must be taken back by the dis
tributor and properly disposed of or be taken to a place of collection. Never dispose of
used batteries in the household refuse.
Please also observe the country-specific regulations.
4.3 Notes on the execution of the maintenance work

The following maintenance work in the maintenance plans is listed in these Maintenance Instructions:
S Cleaning Engine
S Changing Engine Oil
S Changing Oil Filter Elements
S Cleaning Fuel Prefilter
S Fuel Filter - Draining Condensation
S Changing Fuel Filter Element
S Fuel Prefilter with Water Separator - Changing Fuel Filter Cartridge
S Changing Coolant
S Replace air filter element
S Changing Belt
S Checking/Setting Valve Clearance

Maintenance Work
4.4 Maintenance work
4.4.1 Cleaning Engine
DANGER!
Risk of fire caused by highly flammable materials on hot engine parts.
For this reason:
S Regularly clean engine with compressed air.
Regularly clean dirt and dust from the surfaces of the engine using compressed air.
IMPORTANT!
Engine damage caused by water in engine!
If water gets into the inside of the engine this could lead to a total loss of the engine.
For this reason:
S Do not use a high-pressure water cleaner to clean engine.

Maintenance Work
4.4.2 Engine change
WARNING!
Risk of scalding!
Engine oil is hot.
For this reason:
S Always wear protective gloves when handling the oil drain screws.
NOTE!
The oil filter elements are to be changed out at every engine oil change.
Drain engine oil

Drain engine oil with engine at operating temperature.
1. Loosen oil filter cover (1) and unscrew by 2-3

turns.
Engine oil will now flow out of the oil module and
into the oil pan.
A draining time of at least 10 minutes must be
observed.
NOTE!
Use a container with sufficient ca
pacity to change oil (at least 100
litres). This ensures that oil will not
overflow.
2. Position container under the drain screw.

3. Remove oil drain screw (1) from oil pan and
completely drain all oil.
4. Reinstall oil drain screw (1) along with new se
aling ring and tighten.
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . 80 Nm

Maintenance Work
Change Oil Filter Element
A draining time of at least 10 minutes must be

observed.
1. Unscrew and remove oil filter cover (3) along
with O-ring (2) and oil filter element (1).
2. Remove oil filter element (1) and O-ring (2)
from oil filter cover (3).
3. Clean oil filter cover (3).
4. Install new O-ring (2) onto oil filter cover (3).
5. Insert new oil filter element (1) into oil filter co
ver (3).
6. Insert oil filter cover (3) into oil module and tigh
ten.
The further filter elements are changed in the
same way.

Maintenance Work
Filling Engine Oil

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. notch on the oil dipstick.
MAX
MIN
1. Remove cap (1).

2. Slowly fill engine oil into the filler opening.
Oil change amount (with filter):
D2862 LE2.. . . . . . . . . . . . . . . . . . . 93 Litres
3. Reinstall cap (1).
IMPORTANT!
Components can be damaged
due to no oil pressure!
The oil pressure indicator lamp
must go out after engine has run
for 5 seconds.
For this reason:
S Observe oil pressure indicator.
S Check oil pressure and check for
leaks.
S If no oil pressure builds up,
immediately shut down engine.
S Determine cause and rectify pro
blem.
4 Start engine and let it run for a few minutes at

low speed.
5. Shut down the engine.
6. Check engine oil level after 5 minutes.

Maintenance Work
Check Engine Oil Level
NOTE!
Check the oil level when the engine is horizontal and only after at least 5 minutes have
passed since the engine was switched off.
1. Pull out oil dipstick (1).

2. Wipe off oil dipstick with a lint-free cloth.
3. Reinsert oil dipstick all the way.
4. Pull out oil dipstick again 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

Maintenance Work
4.4.3 Clean fuel prefilter
DANGER!
Fire hazard caused by uncontrolled fuel leakage
When opening the fuel system, fuel can leak out uncontrolled.
For this reason:
S Work carefully.
S Do not spill any fuel.
1 Close shutoff valves between engine and tank.

2. Remove filter housing (3).
3. Remove O-ring (2) from filter housing (3).
4. Wash filter housing (3) and fine-mesh filter (1)
in clean diesel fuel and blow off with com
pressed air.
5. Screw on filter housing (3) with fine-mesh filter
(1) and new O-ring (2).
6. Tighten filter housing (3).
7. Bleed fuel prefilter.
Bleed Fuel Prefilter
1. Open shutoff valve between engine and tank.

2. Unscrew plunger (2) of hand pump.
3. Operate plunger (2) of hand pump until over
flow valve audibly opens.
4. Screw on plunger (2) of hand pump again and
tighten.
5. Check fuel prefilter for leaks.

Maintenance Work
4.4.4 Fuel filter - Drain off condensation
DANGER!
For this reason:
S Work carefully.
1. Attach outlet hose to the connections of the

drain screws (1).
2. Unscrew the drain screws (1) a maximum 2
turns and allow the condensate to drain off into
a suitable container.
3. Allow the condensate to flow out until pure fuel
is emerging.
4. Hand tighten the drain plug screws (1).

Maintenance Work
4.4.5 Replace fuel filter element
DANGER!
For this reason:
S Work carefully.

2. Open drain screw (4).
3. Drain fuel into a suitable container.
4. Tighten drain screw (4).
5. Unscrew and remove filter cover (3) along with
O-ring (2).
6. Remove filter element (1).
7. Clean filter cover (3).
8. Insert new filter element (1) into housing.
9. Install new O-ring (2) onto filter cover (3).
10.Screw in and tighten filter cover (3).
The further filter elements are changed in the
same way.
11.Bleed fuel system, see page 41.

Maintenance Work
4.4.6 Fuel pre-filter with water separator - Drain off condensate
DANGER!
For this reason:
S Work carefully.
The fuel prefilter is included as a loose article and is to be installed between the tank and the engine.
1. Open drain screw (1).

2. Drain water into a suitable container.
3. Tighten drain screw (1).

Maintenance Work
4.4.7 Fuel pre-filter with water separator - replace fuel filter cartridge
DANGER!
For this reason:
S Work carefully.

2. Disconnect electrical connector (3).
3. Remove filter bowl (2) and fuel filter cartridge
(1).
4. Clean filter bowl(2).
5. Coat new seal with fuel.
6. Screw on new fuel filter cartridge (1) along with
new seal until seal butts up.
7. Tighten fuel filter cartridge (1) by hand by tur
ning 3/4 of a turn.
8. Install a new seal onto the filter bowl (2).
9. Connect electrical connector (3).
10.Bleed fuel system, see page 41.

Maintenance Work
4.4.8 Bleed fuel system
DANGER!
For this reason:
S Work carefully.
The filter head has an arrow marking the direction of fuel flow.
1. Switch on ignition.
2. Unscrew bleed screws (1) of first filter in the
direction of flow by one or two turns.
3. Unscrew plunger (2) of hand pump.
4. Actuate plunger (1) of the hand pump, until fuel
emerges without bubbles at the bleed screws
(1).
5. Tighten bleed screws (1).
6. Unscrew bleed screws (1) of second filter in the
direction of flow by two turns.
Repeat steps 2-5 for second filter.
7. Screw on plunger (2) of hand pump again and
tighten.
8. Check fuel system for leaks.

Maintenance Work
4.4.9 Change coolant
Drain 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
NOTE!
Do not let coolant spill while draining. Do not let coolant leak out onto the ground or into bo
dies of water otherwise this will damage the environment.
NOTE!
Repeat steps for other side.
1. Unscrew cap at filler neck of expansion

reservoir.
2. Unscrew cap (2) from drain valve.
NOTE!
Use a container with sufficient ca
pacity to drain coolant (depends on
cooling system). This ensures that
coolant will not overflow.
3. Install hose (3) onto drain valve (1).

4. Drain coolant.
5. Remove hose (3) from drain valve.
6 Screw cap (2) at drain valve (1) back on.
6. Screw cap.at filler neck of expansion reservoir
back on.

Maintenance Work
Refilling Coolant
NOTE!
Do not let coolant spill while refilling. Do not let coolant leak out onto the ground or into bo
dies of water otherwise this will damage the environment.
IMPORTANT!
Engine damage caused by excessive temperature difference!
When filling with cold coolant in an engine still hot from operation, there is a risk of dama
ging the engine 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
The cooling system of the engine is to be filled with a mixture of 60% mains drinking water and 40% water-
antifreeze on an ethylene glycol basis.
See Publication “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” in
Operating Instructions.
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 44.
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).

Maintenance Work
4.4.10 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.

Maintenance Work
4.4.11 Replace Poly-V belt
Remove Poly-V belt
WARNING!
Risk of injury!
Poly-V belt tensioner is under tension
For this reason:
S Restrain poly-V belt tensioner to prevent it from springing back
1. Position tool (3) on poly-V belt tensioner (2).

2. Turn poly-V belt tensioner (2) clockwise all the
way and hold.
3. Remove poly-V belt (1).
4. Carefully release the poly-V belt tensioner (2).
Install poly-V belt
CAUTION!
Risk of injury!
Poly-V belt tensioner is under tension
For this reason:
SRestrain poly-V belt tensioner to prevent it from springing back
1. Position tool (3) on poly-V belt tensioner (2).

2. Turn poly-V belt tensioner (2) clockwise all the
way and hold.
3. Install poly-V belt (1).
4. Carefully release the poly-V belt tensioner (2).

Maintenance Work
4.4.12 Replace V-belt
Remove V-belt
1. Loosen and unscrew mounting bolts (2).

2. Remove fan (1).
1. Loosen mounting bolts (1).
1. Loosen locknut nut (2).

2. Turn tensioning screw (1) anticlockwise, until
the V-belt (3) is loose.
2. Remove V-belt (3).

Maintenance Work
Install V-belt
1. Position the V-belt (3).

2. Turn the tensioning screw (1) clockwise, until
the V-belt (3) is tensioned.
3. Tighten lock nut (1).
4. Check V-belt tension, see page 48.
1. Tighten mounting bolts (1).

1. Position fan (1).

2. Screw in and tighten mounting bolts (2).

Maintenance Work
Check V-belt tension
Use the V-belt tension tester to check the V-belt

tension.
1. Lower the indicator arm (1) on the scale.
2. Position the tension tester in centre between
the two belt pulleys, such that the edge of the
contact surface (3) is in just lateral contact on
the V-belt (4).
3. Press slowly and vertically on the pressure pad
(2), until the spring snaps, audibly.3 The indica
tor arm then moves upwards.
Further pressure results in an incorrect indication!
4. The value of the tension force is read off where
the upper edge of the indicator arm (1) in
tersects the scale.
5. Before reading off the value, make sure that the
indicator arm remains in its position.
If the measured value does not correspond with
the prescribed setting value, the V-belt tension
must be corrected.
Initial assembly tension Operating tension Minimum operating

Profile tension
Static drum force Static tension Static tension
(tension) In N In N
In N
KB-4AVX 13 2600  10% 1600  10% 1200

Maintenance Work
4.4.13 Replace air filter cartridge
Remove air filter cartridge
1 Loosen mounting clamp (2).

2 Remove cover (1).
3 Remove air filter cartridge (3) from housing (4).
Install air filter cartridge
1 Clean inside of housing (4).

2 Insert new air filter cartridge (3) in housing (4).
3 Clean cover (1).
4 Fit cover (1) and secure with mounting clamp
(2).
Repeat procedure on the second air filter.
Maintenance indicator
(1). Reset button
(2). Maintenance indicator
With increasing soiling a steadily increasing red

field appears in the window.
If the red field is fully visible in the window, the air
filter is soiled and must be replaced.
After changing the filter the red field is removed by
pressing the reset button.
Indicator: Service when red

Maintenance Work
4.4.14 Replace air filter
Remove air filter
1 Loosen the hose clamp (2).

2 Remove air filter (1).
Install air filter
1 Position new air filter (1).

2 Position hose clamp (2) and tighten.

Maintenance Work
4.4.15 Check valve clearance and adjust
IMPORTANT!
Engine damage caused by incorrectly set valves
For this reason:
S Only set valves with the engine cold (< 50)
Special tools
Item Special tool Purpose Item‐ number

1 Engine cranking device Turing engine in combination with gear rat 80.99626-6009
chet, Item. 2
2 Gear ratchet Turing engine in combination with engine 80.99627-0001
cranking device, Item. 1
3 Mount Check and set valve clearance in combina 08.75300-0000
tion with:
• Feeler gauge blade 0.5, Item. 4
• Feeler gauge blade 0.8, Item. 5
• Valve setting wrench, size 14, Item. 6
4 Feeler gauge blade 0.5 Check and set valve clearance in combina 80.99607-0177
tion with:
• Mount, Item. 3
5 Feeler gauge blade 0.8 Check and set valve clearance in combina 80.99607-0179
tion with:
• Mount, Item. 3
6 Valve setting wrench, size 14 Set valve clearance in combination with 80.99603-6031
handle, Item. 7
7 Handle Adjust valve clearance in conjunction with 08.06460-0003
valve adjusting tool SW 14, Item. 6

Maintenance Work
Remove cylinder 1 cylinder cover

1. Remove mounting bolts (1).
2. Remove cylinder head cover (2).
Install engine cranking device

1. Remove cap along with seal and timing marker
plate from the flywheel housing.
2. Install engine cranking device [1] (1) onto fly
wheel housing.
Rotate engine to setting position

A = Rocker arm in overlap
B = Rocker arm free for setting clearance
1. Rotate engine with the gear ratchet [2] until ro
cker arm is in overlap.
2. Set the corresponding free rocker arm
(see table)

Maintenance Work
Check valve clearance of intake valve

Slide mount [3] (3) with feeler gauge blade 0.5 [4]
(4) between the valve bridge (1) and ball socket
(2).
If the valve clearance is not 0.50 mm, set valve
clearance.
Set valve clearance of intake valve

1. Loosen jam nut (3).
2. Unscrew adjustment screw (2) until the mount
[3] (5) with feeler gauge blade 0.5 [4] (6) can be
slid between the ball socket (4) and valve
bridge (1).
3. Screw in the adjustment screw (2) until the
mount [3] (5) with feeler gauge blade 0.5 [4] (6)
can be moved with a small amount of
resistance between the ball socket (4) and
valve bridge (1).
4. Install the valve setting wrench, size 14 [6], with
handle [7] on the adjustment screw (2) and jam
nut (3).
5. Restrain adjustment screw (2) using valve
setting wrench, size 14 [6] .
6 Tighten jam nut (3) with 45 Nm using valve
setting wrench, size 14 [6] .
7. Recheck setting.
Check valve clearance of exhaust valve

Slide mount [3] (3) with feeler gauge blade 0.8 [5]
(4) between the valve bridge (1) and ball socket
(2).
If the valve clearance is not 0.80 mm, set valve
clearance.

Maintenance Work
Set valve clearance of exhaust valve

1. Loosen jam nut (3).
2. Unscrew adjustment screw (2) until the mount
[3] (5) with feeler gauge blade 0.8 [5] (6) can be
slid between the ball socket (4) and valve
bridge (1).
3. Screw in the adjustment screw (2) until the
mount [3] (5) with feeler gauge blade 0.8 [5] (6)
can be moved with a small amount of
resistance between the ball socket (4) and
valve bridge (1).
4. Install the valve setting wrench, size 14 [6]
, with handle [7] on the adjustment screw (2) and
jam nut (3).
5. Restrain adjustment screw (2) using valve
setting wrench, size 14 [6].
6. Tighten jam nut (3) with 45 Nm using valve
setting wrench, size 14 [6].
7. Recheck setting.
Install cylinder head cover

1. Set on cylinder head cover (2).
2. Screw in and tighten mounting bolts (1).

Maintenance Work

Decommissioning and Recommissioning
5 Decommissioning and recommissioning
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 Safety Shoes
S Safety Gloves
5.2 Safety instructions
Personnel
S Decommissioning and recommissioning of the engine may only be undertaken by trained and qualified
personnel.
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 by unauthorised persons.
S Perform all work steps in accordance with the instructions in these Operating Instructions.
S Ensure adequate work space before starting any work.
S Make sure work space is kept clean and orderly! Any unused parts or components lying
around are potential sources of accidents.

5.3 Temporary decommissioning of the engine

During long decommissioning periods the engine is exposed to the corrosive effects of its immediate sur
roundings. The humidity of the ambient air and the formation of condensation when the dew point is rea
ched especially lead to corrosion damage to cylinder liners, piston rings and valves.
IMPORTANT!
Corrosion damage to cylinder liners, piston rings and valves after long periods of
decommissioning.
The ingress of foreign matter can make it necessary to completely take apart the engine.
For this reason:
S Observe the measures for protection against corrosion.
5.3.1 Decommissioning the engine for up to 3 months

Even simple measures taken before temporary decommissioning of the engine can provide an effective
protection against corrosion:
S Thoroughly clean the outside of the engine with compressed air. Eliminate dirt and dust and dry the sur
faces of the engine.
S Fill fuel tank with diesel fuel.
S Adjust and ensure that the mixing ratio and concentration of the antifreeze in the coolant meets the
requirements; see publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.
S Close off all engine openings (for intake air and exhaust) to prevent any exchange of air with the interior
of the engine.

5.3.2 Decommissioning of the engine for between 3 and 12 months

If the engine is to be decommissioned for longer than 3 months, engine preservation is required in addition
to the measures listed under 5.3.1.
NOTE!
Compliance with engine preservation procedures when the engine is taken aut of service
temporarily is a basic prerequisite for maintaining the warranty.
Preservation of the fuel system

The fuel system and the combustion chambers of the engine are preserved due to operation with corrosion
protection fuel. Corrosion protection fuel is a mixture of conventional diesel fuel DIN EN 590 and
2 Vol% corrosion inhibitor Autol Desolite K (MAN item number 09.14002-0035), see MAN works standard
M 3069.
Preservation of the fuel system is to be carried out as follows:
S Drain diesel fuel without corrosion protection from the tank.
S Fill the tank with corrosion protection fuel.
S Operate the engine at medium speed for approx 10 minutes so that the entire fuel system is filled with
corrosion protection fuel.
S Shut down engine.
S With the air intake opening closed, crank the engine 30 seconds with the starter.
IMPORTANT!
Risk of component damage due to incorrect preservation
Damage to the engine on restarting
For this reason:
S Close the openings for intake air so that they ar air-tight.
S While cranking he engine with the starter, the engine should not startup, that means a
combustion must be avoided.
S Supply power to the control unit so that injection takes places according to the starting
characteristic map.
S Afterwards tightly seal all openings on the combustion chamber side (including the muffler) to
permanantly maintain the preservation.
Therby the combustion chambers, cylinder liners, valves and the injection equipment are preserved.
The works standard M 3069 is available from the customer service department at the Nuremberg factory.
Preservation of the intake and exhaust systems

S Spray anticorrosion oil (MAN part number 09.11002-0025) into the air intake pipe and exhaust pipe.
S Close off openings for intake air and exhaust airtight while engine is still warm.
The works standard is available from the customer service department at the Nuremberg factory.

5.4 Recommissioning of decommissioned engines

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.
The requirements in the MAN-Werknorm M3069 are to be met.
NOTE!
Engines are preserved ex-works with a preservation agent according to Werknorm 3069.
The works norm can be obtained from the After-Sales Service department at the Nurem
berg works.
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 en
gine is stored in the open. Foreign matter, rain water and similar conditions require a complete disassembly
of the engine.
For this reason one must differentiate between preserved and non-preserved engines when placing them
back into commission:
5.4.1 Commissioning of preserved engines in accordance with MAN-Werknorm

(works standard) 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, fill with water-antifreeze in accordance with the list of operating fuels, lubricants
and fluids (see the publication “Operating fuels, lubricants and fluids ..."), check concentration and cor
rect if necessary.
4. Check engine oil level and add fresh approved engine oil if necessary.
5. 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. Start engine and observe whether the oil pressure builds up. The oil pressure indicator lamp must go
out after the engine has run for 5 seconds at the latest.
8. After engine is running on its own, do not let it idle at a low rpm. This is to ensure that the cylinder liners
receive sufficient lubrication.
9. Check engine for any possible oil leaks or abnormal noises. Keep an eye on the oil pressure and tempe
ratures. Increase engine speed in steps.
10.The preservation oil must be drained from the engine and the oil filter must be changed after 25 opera
ting hours at the latest. Refill with fresh approved engine oil.

5.4.2 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 exhaust turbocharger for soiling, onset of corrosion. Clean or repair
as necessary.
5. Clean fuel system, if necessary drain off old fuel, replace fuel filter, clean fuel pre-filter.


Maintenance Record
6 Maintenance Record
For maintenance work according to M1 to M6, page 64
For maintenance work according to A, page 74

Maintenance Record

Maintenance Record
500
Location
Performed at operating hours
Maintenance according to Operating Hours M2 M3 M4 M5 M6

(check maintenance work performed)
Maintenance according to Time Intervals M2 M3 M4 M5 M6

Product name of engine oil
Viscosity class
Next maintenance
(date and/or operating hours)
Stamp, Date, Signature
1000
Location


Viscosity class
Next maintenance

Maintenance Record
1500
Location


Viscosity class
Next maintenance
2000
Location


Viscosity class
Next maintenance

Maintenance Record
2500
Location


Viscosity class
Next maintenance
3000
Location


Viscosity class
Next maintenance

Maintenance Record
3500
Location


Viscosity class
Next maintenance
4000
Location


Viscosity class
Next maintenance

Maintenance Record
4500
Location


Viscosity class
Next maintenance
5000
Location


Viscosity class
Next maintenance

Maintenance Record
5500
Location


Viscosity class
Next maintenance
6000
Location


Viscosity class
Next maintenance

Maintenance Record
6500
Location


Viscosity class
Next maintenance
7000
Location


Viscosity class
Next maintenance

Maintenance Record
7500
Location


Viscosity class
Next maintenance
8000
Location


Viscosity class
Next maintenance

Maintenance Record
8500
Location


Viscosity class
Next maintenance
9000
Location


Viscosity class
Next maintenance

Maintenance Record
9500
Location


Viscosity class
Next maintenance
10000
Location


Viscosity class
Next maintenance

Maintenance Record
4 Years
Location
Date
Stamp, Signature
8 Years
Location
Date
Stamp, Signature

Maintenance Record
12 Years
Location
Date
Stamp, Signature
16 Years
Location
Date
Stamp, Signature

MAN Truck & Bus AG
90441 Nürnberg
Germany
A company in the MAN Group
Printed in Germany 51.99597-8022

MAN Truck & Bus AG
90441 Nuremberg
Germany
man-engines@man.eu
www.man-engines.com
MAN Truck & Bus – a member of the MAN Group

Maintenance Manual: MAN Industrial Diesel Engines D2862 LE221/223/231/233

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Maintenance Manual: MAN Industrial Diesel Engines D2862 LE221/223/231/233

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Maintenance Manual

MAN Industrial Diesel Engines

MAN Industrial Diesel Engines

D2862 LE221 / LE223 / LE231 / LE233

51.99597-8022 “Translation of the original maintenance instructions”

Technical status: 02.2018

Carefully read the Maintenance Instructions before starting any work!

Information and Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4 Transport, packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Carefully read the Assembly Instructions before starting any work!

7 Installation drawing for the engines D2862 LE221/223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Carefully read the Assembly Instructions before starting any work!

1.1 Information on the maintenance instruction

1.1.1 Supplementary information relating to the maintenance instruction

For the service personnel

Carefully read the Maintenance Instructions before starting any work!

1.2 Key to Symbols

Tips and Recommendations

Carefully read the Maintenance Instructions before starting any work!

1.3 Restriction of liability

1.5 Relevant publications

Carefully read the Maintenance Instructions before starting any work!

1.6 Spare parts

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

Carefully read the Maintenance Instructions before starting any work!

1.8 Warranty conditions

1.9 Customer service

Carefully read the Maintenance Instructions before starting any work!

Carefully read the Maintenance Instructions before starting any work!

2 General Safety Instructions

2.1 Intended Use

Carefully read the Maintenance Instructions before starting any work!

2.2 Content of the maintenance instruction

2.3 Modifications and Conversions to the Engine

2.4 Responsibility of the Operator

Carefully read the Maintenance Instructions before starting any work!

2.5 Personnel Requirements

2.5.2 Unauthorised persons

Carefully read the Maintenance Instructions before starting any work!

2.6 Personal Protective Equipment

To be worn when performing specific types of work

Carefully read the Maintenance Instructions before starting any work!

2.7 Specific Dangers

Carefully read the Maintenance Instructions before starting any work!

Highly Flammable Substances - Diesel Fuel, Oils and Grease

Coolants - Antifreeze, Anticorrosion Agents

Hot Fluids and Lubricants

Carefully read the Maintenance Instructions before starting any work!

Sharp Edges and Corners

Dirt and Objects

Carefully read the Maintenance Instructions before starting any work!

Working on the Common Rail System

Carefully read the Maintenance Instructions before starting any work!

Carefully read the Maintenance Instructions before starting any work!

2.8 Safety Equipment

2.8.1 Emergency-Stop device

2.8.2 Belt guards

2.8.3 Fan protective cover

2.8.4 Heat protection for exhaust pipe and turbine housing

Carefully read the Maintenance Instructions before starting any work!

2.9 Conduct in Dangerous Situations and When Accidents Occur