Operating Instruction: MAN Marine Diesel Engines D2868 LE4XX / D2862 LE4XX

Operating Instruction
MAN Marine Diesel Engines

D2868 LE4XX / D2862 LE4XX
MAN Engines
Operating Instruction
MAN Marine Diesel Engines
D2868 LE4XX / D2862 LE4XX
51.99587-5056 "Original instruction"

Version 01
Imprint
Subject to change without prior notice.

All information, texts, drawings, figures and other content are protected by copyright law and subject to
industrial property rights. Any improper use shall be liable to prosecution.
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.
Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without the
prior written approval of MAN Truck & Bus. All rights deriving from copyright law are expressly reserved by
MAN.
MAN Truck & Bus SE

Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
E-Mail: Engine-Documentation@man.eu
Internet: www.engines.man.eu
Technical status as on: 09/2019

51.99587-5056
Read these instructions carefully before starting any work!

This is particularly applicable to the chapter "General Safety Instructions"
2 and the respective safety instructions in the chapters.
Table of contents
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information about these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Explanation of icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Limitation on liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Warranty provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Content of these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Modifications and conversions to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Requirements of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.9 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10 Conduct in the event of hazards and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.11 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.12 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Engine type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Explanation of engine no. (engine identification number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Explanation of type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Information on the engine type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 Emission label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Design and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.1 Fields of application for the engines with aftertreatment system . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Engine body and engine equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Engine views D2862 LE4xx (1-stage turbocharged) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Transport, packaging and storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

and the respective safety instructions in the chapters. 3
Table of contents
6 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.3 Installation of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4 Completing the engine and assembling the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.5 System installation in the ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.6 Connecting the oil filter (Version 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.7 Connecting the oil filter (Version 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.8 Connecting the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.9 Connecting the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.10 Attaching the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.11 Connecting the cabin heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.12 PTO/hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.13 Connecting the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.14 Attaching the protective device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.15 Plugs on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.16 Torque values for screw connections according to the M 3059 factory standard . . . . . . . . 68
6.17 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7 Control and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3 Preparations prior to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.4 Switching the fuel pre-filter/fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.5 Switching the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.6 Daily inspection before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.7 Starting and stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.8 Operating engine in ship mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.1 Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2 Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10 Decommissioning and recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

10.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.3 Taking the engine out of operation temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.4 Restarting engines that have been shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.5 Decommissioning and recommissioning of the DEF/AdBlue®/AUS32 system . . . . . . . . . 94

Table of contents
11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.1 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.2 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.3 Requirements for the installation site and space requirements . . . . . . . . . . . . . . . . . . . . . . . 95
11.4 Engine data - Light duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11.5 Engine data - Medium duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
11.6 Engine data - Heavy duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12 Installation drawing D2862 LE4XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
13 Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
13.2 Keyword Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Table of contents

Preface
1 Preface
These instructions apply to the following engines:
Engine types Output in kW Nominal speed Emission level Aftertreatment system

Yes No
Light duty
D2868 LE466 956 IMO Tier II / US Tier 3 x
D2862 LE496 1471 2300 IMO Tier II / US Tier 3 x
D2862 LE459 1213 IMO Tier III x
Medium duty
D2862 LE428 749 IMO Tier III / US Tier 4 x
2100
Heavy duty
D2862 LE437 551 1800 IMO Tier III x
1.1 Information about these instructions

These instructions contains information on assembly, operation and maintenance of the engine.
The requirement for working safely is to follow all instructions on safety and work.
Moreover, the local accident prevention regulations applicable and general provisions on safety for the
application area of the engine must be followed.
Timely and conscientious maintenance and care at the specified service intervals ensure and maintain the
operating safety, as well as the reliable use of your engine.
Use only genuine MAN spare parts and accessories or those that have been approved by MAN.
Only genuine spare parts that we have approved are checked by us and therefore possess proper
requirements for engine use.
MAN places great importance on improving environmental protection.
This begins as early as the design and development stage of our engines. We take great care to ensure
that no materials which are harmful to the environment are used and that, for example, emission values
meet the highest statutory requirements.
Efficient operation contributes to the conservation of our resources and our environment.

Preface
1.1.1 Supplementary publications to these instructions

These operating instructions include the publications
- Service products for MAN industrial and marine diesel engines
- Maintenance Manual
All documents are parts of the product and must be kept near the engine so that they can be accessed by
the personnel whenever required.
Read these instructions carefully before starting any work! This is particularly applicable to the chapter
"General Safety Instructions" and the respective safety instructions in the chapters.
Ignoring these instructions and any Operating Instructions of suppliers enclosed leads to warranty claims
becoming null and void.
1.1.2 Other publications

The following instructions are available as supplements to these instructions:
- Spare parts catalog (included in the scope of supply)
- Installation Instructions
- Operating Instructions „MAN Intelligent Marine Safeguard System“ (iSea / iSea Class)
In addition, for engines with aftertreatment system
- (Emission-related) Installation instructions - Modular aftertreatment system, marine
- Maintenance Manual - Modular aftertreatment system, marine

Preface
1.2 Explanation of icons
Warnings
Warnings in these instructions are identified by icons. The information has been introduced with
signal words that express the extent of risk or danger.
Follow the instructions in all cases and proceed with care in order to prevent accidents, personal injury and
material damage.
DANGER
Describes an immediate hazardous situation that will lead to severe or fatal injuries if it is not avoided.
WARNING
Describes a potentially hazardous situation that may lead to severe or fatal injuries if it is not avoided.
CAUTION
Describes a potentially hazardous situation that may lead to minor or moderate injuries if it is not
avoided.
NOTICE
Describes a potentially hazardous situation that may lead to damage to property if it is not avoided.
Tips and Recommendations
Tip for users

Tips and recommendations as well as information for efficient and trouble-free operation.
ENVIRONMENTAL WARNING
Tips on conduct for environmental protection.
General notices
• This sign indicates a list in the first level.
► This symbol indicates an action or series of actions.
[1] This symbol indicates the position of a special tool after the list in the chapter
(1) This symbol indicates the position of a graphic in the text.
1 This symbol displays the position of a graphic in the text.

Preface
1.3 Limitation on liability

All information and notices in these instructions have been compiled taking into consideration the applicable
standards and regulations, the state-of-the-art technology as well as our knowledge and experience
acquired over a period of several years.
MAN does not assume any liability for damage caused as a result of:
S Disregarding these instructions
S Improper or unintended use
S Use of untrained personnel
S Unauthorized conversions
S Technical modifications
S Use of unapproved spare parts and service products
In case of special designs, the actual scope of supply, the use of additional ordering options or on account
of the latest technical modifications may vary from the explanations and illustrations described here.
The obligations agreed upon in the supply contract and the general terms and conditions of MAN, and the
statutory regulations valid at the time of concluding the contract shall be applicable.
1.4 Copyright protection

Treat the instructions as confidential. It is meant only for those working with the engine.
Handing over the maintenance instructions to third parties without express written consent from MAN is
forbidden.
Tip for users

All information, texts, drawings, figures and other content are protected by copyright law and subject to
industrial property rights.
Any improper use shall be liable to prosecution.
1.5 Other applicable documents

Installed in the engine and suppliers' components (e.g. injection system). The respective suppliers of these
supplied components have carried out risk assessments for them.
The compatibility of the design with the applicable European and national regulations has been declared by
the respective suppliers of the components.

Preface
1.6 Spare parts

Maintenance, repair or replacement of spare parts can be performed by any authorized service and repair
branch without impacting the emissions parts while doing so.
As a prerequisite, the repairs must be carried out in accordance with the manufacturer specifications and
the spare parts must be at least equivalent to genuine MAN parts in terms of emission behavior and
durability. However, warranty repairs and replacements must be carried out by an authorized MAN dealer.
We recommend using exclusively original MAN spare parts and accessories or parts approved by MAN.
Only MAN approved original spare parts are checked by us and thus possess the suitable prerequisites for
using the engine.
In the event that genuine MAN spare parts are not used, the proprietors should ensure that such parts are
guaranteed by the manufacturer and are at least equivalent to genuine MAN parts in terms of emission
behavior and durability. Despite ongoing market observation, we cannot assess this for other products nor
certify the same.
WARNING
Risk of injury from incorrect spare parts
Use of incorrect or defective spare parts may lead to damage, malfunctions or total failure, affect
emission behavior and may also affect safety.
For this reason:
S Suggestion: Use only genuine MAN spare parts
Tip for users

Please mention the engine type, engine number and the order number with all communication.
Order spare parts from an authorized dealer or directly from MAN.

Address, see page 2.
1.7 Disposal
Arrange for disposal in accordance with national regulations.
Send dismantled or disassembled components for recycling provided that there is no agreement on
sending them back or arranging for their disposal:
S Sort metallic parts and scrap them
S Send plastic elements for recycling
S Dispose of other components sorted according to the material properties
S Handling service products, see page 25

Preface
1.8 Warranty provisions

The obligations agreed upon in the supply contract and the general terms and conditions of MAN, and the
statutory regulations valid at the time of concluding the contract shall be applicable.
Ignoring these instructions and any Operating Instructions of suppliers enclosed leads to warranty claims
becoming null and void.
If you use parts that are not approved, warranty claims shall become null and void.
We recommend that you use genuine parts even after expiration of the warranty period in order to ensure
consistent performance of the engine.
1.9 Customer service

The MAN customer service is at your disposal for technical information.
Tip for users

Information on the contact persons in charge can be retrieved whenever required via telephone, e-mail or
via the Internet. Address, see page 2.

General safety instructions
2 General safety instructions

This chapter contains safety instructions that must be taken into account already in the planning phase.
These instructions guarantee maximum protection of personnel and safe, trouble-free engine operation.
Additional safety instructions must be observed during the assembly and commissioning of the engine.
MAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are not all inclusive. If a tool, a procedure, a work method, or an
operating technique is used that is not specifically recommended by MAN, you must be certain that it is
safe for you and for other people. You must also be certain that the product will not be damaged. You must
also be certain that the safety of the product is not affected by the procedures that are used.
Most industrial accidents occur during the installation, operation, maintenance and repair of the products
and are caused due to non-compliance with basic safety regulations and protective measures. An accident
can often be avoided by recognizing potentially hazardous situations before an accident occurs.
An technician must be alert to potential hazards. The technician must also have the necessary training,
skills and tools in order to perform these works properly. The information in this publication was based upon
current information at the time of publication. Check for the most current information before you start any
job. The latest information can be provided by your MAN dealer.
2.1 Proper use

All engines described in these instructions are suitable for commercial operation and depending on the
type, suited to heavy, medium or light duty.
The operating mode is defined by the expected operating hours per year and the percentage of full load as
well as the average utilization.
An engine must only be installed for the specified application (e.g. fixed pitch propeller), for which it has
been certified and accepted.
The certification status can be found on the emissions type plate on the engine.
Any other use is classified as not in accordance with the designated use.
MAN accepts no liability for damage resulting from this. The operator alone shall bear this risk.
Proper use also includes compliance with the operating, maintenance and service work specified by the
manufacturer.
The engine must only be installed and put into service by personnel who are familiar with it and have been
instructed about potential dangers.
The manufacturer does not assume any liability for damage to property or personal injury resulting from
unauthorized modifications to the engine.
Tampering with the electronics and injection and control system may also affect the performance and
exhaust gas behavior of the engine.
This means that compliance with the statutory environmental requirements is no longer assured.
DANGER
Risk of damages to the engine due to improper use
Expiry of operating permit.
For this reason:
S Use the engine only for the approved application.

2.2 Content of these instructions

Each person appointed to work on or with the engine must read and understand these instructions before
doing any work on the engine. This is also applicable if the concerned person has already worked with such
an engine or a similar one or has been trained by MAN.
Thus, knowledge of these instructions is mandatory.
2.3 Modifications and conversions to the engine

To avoid dangers and to safeguard optimal performance, neither modifications nor attachments or
conversions should be made on the engine or the aftertreatment system that have not been expressly
approved by MAN.
If modifications are made without the written consent of MAN, any obligation of guarantee or warranty on
the part of MAN for damage and defects that are attributable to the unauthorized modification becomes null
and void. Moreover, MAN does not assume any liability for damage that are caused by modifications that
have not been approved.
2.4 Responsibility of the operating company

The operating company is subject to the statutory obligations of industrial safety.
In addition to the notices on industrial safety in these instructions, the safety, accident prevention and
environmental protection regulations applicable for the area of application of the engine must be obeyed.
In doing so, the following is particularly applicable:
S The operating company must be aware of the applicable provisions of industrial safety and it must
determine additional dangers in a risk assessment that may arise based on the special working
conditions where the engine is used. The operating company must implement these in the form of
operational instructions for operating the engine.
S During the total operating time of the engine, the operating company must check that the operating
instructions created by the company correspond to the current regulations and must adapt these
instructions if necessary.
S The operating company must clearly regulate and specify the responsibilities for installation, operation,
maintenance and cleaning.
S The operating company must ensure that all employees who work with the engine have read and
understood the operating instructions.
Moreover, the operating company must train the personnel at regular intervals and inform them about
the risks involved.
S The operating company must provide the required protective equipment necessary for the personnel.
S These Operating Instructions must be kept near the engine and must be accessible to all persons
working with the engine whenever required.
The operating company is responsible for ensuring that the engine is always operated in technically sound
and operationally safe condition.
Hence, the following is applicable:
S Do maintenance work as it has been described in these instructions and in the maintenance instructions
completely and at the intervals specified, or have it done by a MAN service workshop / MAN authorized
partner.
S The operating company must have all safety equipment and devices checked regularly for
completeness and functionality.
S The information in the instructions must be followed completely and without any restrictions!

2.5 Requirements of personnel
2.5.1 Qualifications
WARNING
Risk of injury caused by untrained personnel
Ignoring the safety regulations poses the risk of injury to personnel.
For this reason:
S Carry out all work steps in accordance with the information in these instructions.
S Have the engine serviced and repaired only by trained personnel.
S Ensure that the engine cannot be started by unauthorized persons.
S Regular attendance at product and user training.
S Observe safety and accident prevention regulations.
S Ensure orderliness and cleanliness in the working area.
Tip for users

MAN Truck & Bus SE regularly provides product and application training. These training sessions can
provide the necessary expertise.
Contact information for the MAN Engine Academy.
http://www.engines.man.eu/global/de/ueber-man-engines/man-engine-academy/Themen.html
The following qualifications are mentioned in the instructions for various areas of activity:
S A trained person
has been briefed about their assigned duties and informed about potential hazards in case of improper
conduct.
S Qualified personnel
are people who, based on their technical education, knowledge and experience as well as knowledge of
the relevant regulations, are capable of carrying out the duties assigned to them professionally.
S A qualified electrical technician
is someone who, based on his technical education, knowledge and experience as well as knowledge of
the relevant standards and regulations, is capable of working on electrical systems, identifying potential
hazards on his own and avoiding them.
The qualified electrical technician is trained for the special location where he is working and is familiar
with the relevant standards and regulations.
Only persons who can be expected to carry out their work reliably may be approved as personnel. Persons
whose reflexes are affected, e.g. by drugs, alcohol or medicines, are not approved.
S When choosing personnel, obey the regulations concerning age and profession applicable at the place
of work.
2.5.2 Unauthorized persons
WARNING
Risk of injury for unauthorized persons
For this reason:
S Keep unauthorized persons away from the working area.
S In case of doubt, talk to the persons and instruct them to leave the working area.
S Stop work as long as unauthorized persons remain in the working area.

2.5.3 Training
The personnel must be briefed and trained regularly. The training must be recorded for better tracking of
the training.
2.6 Personal protective equipment

It is necessary to wear personal protective equipment in order to minimize the risks to health while working.
S Always wear the necessary personal protective equipment whilst carrying out any work.
S Obey the signs present in the working area regarding personal protective equipment.
Industrial protective clothing

is tight-fitting work clothing with low tear strength, with tight-fitting sleeves and without
protruding parts. They are used primarily to protect against injuries, climatic influences
and dirt or contamination.
Do not wear any rings, necklaces or other jewelry on the body while working.
Hard hat
for protection against parts falling down or flying around.
Safety shoes
to protect against heavy falling parts and slipping on slippery surfaces.
Safety gloves
to protect hands from abrasion, getting pricked or deep injuries as well as from coming
into contact with hot or corrosive parts or liquids.
Clothing for special work

When doing special work, special protective equipment is necessary. Special reference is made to these in
the various chapters of these instructions.
Safety goggles
to protect the eyes from parts flying around and liquid sprays.
Ear protection
to protect against hearing loss caused by noise.

2.7 Special hazards

Residual risks that have been determined are mentioned in the following section.
S Observe and follow the safety instructions listed here and the warnings in other chapters of these
instructions in order to mitigate risks to health and to avoid hazardous situations.
Electrical current
DANGER
Risk of life from electrical voltage
For this reason:

S If the insulation of the voltage supply gets damaged, shut it down immediately and initiate its repair.
S Have work carried out on the electrical system only by electricians.
S For carrying out any work on the electrical system, deenergize the system and check that it is
deenergized.
S Shut off the voltage supply and secure it from being switched on again before completing
maintenance, cleaning or repair work.
S Do not bypass or disable any fuses. Replace fuses with those having the correct amperage rating.
S Keep moisture away from live parts. It can lead to a short circuit.
Moving components
WARNING
Risk of injury from freely rotating components
For this reason:

S During operation, do not reach into moving components or put your hands on moving components.
S Do not open covers during operation.
S Do testing and maintenance work only when the engine is completely stopped.
S Pay attention to the time delay: Before opening the covers ensure that parts are not moving any
longer.
S Wear close-fitting work clothing in the hazard zone.
Flying parts in the event of sudden engine damage
WARNING
Risk of injury from running engines
In case of damage to engines, components may fly through the engine room at a high level of energy
and injure persons in the immediate vicinity.
For this reason:
S No one is allowed in the engine room when the engine is running.

Exhaust gases
WARNING
Health hazard due to a leaky exhaust system
For this reason:

S Decommission machines with leaking exhaust systems immediately.
S Repair leaking exhaust system.
S Ensure adequate ventilation.
Easily inflammable materials - diesel fuel, oils and greases
WARNING
Risk of injury from easily inflammable substances
Risk of fire from highly flammable materials, liquids and gases.
For this reason:
S Smoking is forbidden in the hazard zone.
S Working with open flames and sources of ignition in the hazard zone is forbidden.
S Keep fire extinguishers ready for use.
S Report suspicious substances, liquids or gases immediately to the person in charge.
S Discontinue work immediately in case of fire. Leave the danger zone until given the all clear.
Coolants - antifreeze and anti-corrosion agent
WARNING
Risk of injury from coolants harmful to health
Coolant contains substances that are harmful to health.
For this reason:
S Observe and follow the safety data sheets of the manufacturers.
S Wear personal protective equipment.
S Avoid contact with the eyes and skin.
S Avoid spilling and mist formation.
Hot service products
CAUTION
Risk of scalding by hot service products
Service products reach high temperatures and cause burns.
For this reason:
S Allow service products to cool down.
S If necessary, wear additional ear protection, a safety mask, safety goggles, and chemical-resistant
gloves.
S In the event of injury, consult a doctor immediately.
S Observe safety data sheets.
S Follow the accident prevention regulations.
S Observe workplace safety regulations.

Hot surfaces
CAUTION
Risk of burn injuries caused by hot surfaces
Components reach high temperatures during operation and cause scalding if they come into contact.
For this reason:
S Wear personal protective equipment and safety gloves.
S Allow components to cool down to ambient temperature.
S Ensure that protective devices is never removed from hot components.
Noise
WARNING
Risk of hearing impairment caused by noise
For this reason:

S Always wear ear protection while carrying out any work.
S Remain in the hazard zone only as long as necessary.
Sharp edges, pointed corners, dirt or objects lying around
CAUTION
Risk of injury from disregarding accident prevention regulations
For this reason:


Work on the Common Rail system
CAUTION
Risk of injury from escaping liquids
Liquid jet gets released under high pressure.
For this reason:
S Wear additional hearing protection, a safety mask, and protective googles.
S Shut down the engine and wait until the pressure has fallen before starting work.
S Observe accident prevention regulations.
CAUTION
Risk of life from defective lines
Liquid jet gets released under high pressure.
For this reason:
S Never touch the liquid jet.
S Shut down the engine immediately.
S If necessary, initiate further measures to reduce the pressure and stop the liquid jet.
S Absorb liquids that have leaked out properly and arrange for their disposal.
S Replace defective parts.
DANGER
Risk of life from strong magnetic fields
For this reason:

S Persons with pacemakers must not stay near the engine.
S Persons with metallic implants must not stay near the engine.
S Keep ferromagnetic materials and electromagnets away from the magnetic source
(minimum distance: 3 m).
S Put metallic objects (jewelry, watches and writing instruments, etc.) away before carrying out
maintenance work.
S Do not bring any electronic devices near the magnetic source.
S Do not bring any storage media, credit cards, etc., near the magnetic source.

Hydraulic System
WARNING
Risk of injury from hydraulic sources
For this reason:
S Have work done on the hydraulic system only by trained specialists.
S Before starting any work on the hydraulic system, first switch it off and de-pressurize it.
S Relieve the pressure tank completely. Check for depressurized condition.
S Do not change pressure settings beyond the maximum values.
S Wear chemical-resistant safety gloves.
Cable harnesses and plug connectors
NOTICE
Risk of damage to components caused by incorrect handling
Irreparable damage to plug connectors and EDC control units from spread contacts and damaged
contacts.
For this reason:
S When installing, the plug first open the plug lock completely and then insert the plug connector and
lock it.
S Protect removed plug connectors and contacts against dirt.
S Check cable harnesses and plug connectors only with a suitable test device (bushing box).
S Connect/disconnect the plug connectors of electronic control units only when the ignition is switched off.
Electric welding
NOTICE
Risk of material damage due to incorrect handling of welding equipment
Damage to components and the electronics system due to electric arc welding.
For this reason:
S Welding works of any kind may be carried out only after consultation with the system supplier or as
per his specifications.
S MAN shall not assume any liability for damages, especially to the engine electronics, that occur due to
improperly performed welding works.

2.8 Safety equipment
The operating company must retrofit the following safety equipment:

Install emergency-stop device before the engine is put into operation and link to the system’s safety chain.
Connect the emergency stop equipment in such a manner that in case of an interruption of the power
supply or restoration of power supply after an interruption, hazardous situations for human beings and
property are ruled out.
The emergency stop facility must always be easily accessible.
DANGER
Risk of life from non-functional safety equipment and devices
For this reason:

S Before beginning work, check whether all safety equipment is functional and correctly installed.
S Prior to starting the engine, check whether all safety equipment is functional and correctly installed.
S Never disable safety equipment or devices during operation.
2.9 Protective devices
The operating company must retrofit the following protective devices:

The V-belt cover included in the scope of supply is not a protective device. Before putting the engine into
operation, suitable protective devices must be implemented.
DANGER
Risk of life due to inadequate protective devices
The V-belt cover included in the scope of supply is not a protective device.
For this reason:
S Implement suitable protective devices before putting the engine into operation.

2.10 Conduct in the event of hazards and accidents
Preventive measures
S Always be prepared for accidents or fire!
S Keep first-aid equipment (first-aid box, blankets, etc.) and fire extinguishers readily accessible.
S Check the first-aid equipment and fire extinguishers regularly for completeness and functionality.
S Familiarize persons with accident reporting, first-aid and rescue equipment.
S Conduct training and drills on safety regularly.
S Keep entry routes clear for ambulance vehicles.
CAUTION
Improper conduct may pose a safety hazard
For this reason:

S Remain calm in the event of an accident.
S Shut down the engine.
S Initiate first-aid measures
S Raise an alarm with ambulance and / or fire department.
CAUTION
Risk of injury from harmful service products
For this reason:

S If necessary, wear additional hearing protection, a safety mask, protective goggles, and chemical-
resistant safety gloves.
S Avoid contact with the eyes and skin.
S Do not eat, drink or smoke at the workplace.
S Wash hands thoroughly when finished working.
S Remove contaminated clothing immediately.
S Avoid any spillage of service products.
S Observe safety data sheets.
S Use an extraction system as required.
CAUTION
Risk of injury from disregarding accident prevention regulations
For this reason:


2.11 Signage
The following icons should be placed near the hazard zone.
WARNING
Risk of injury from illegible icons
Over time, stickers and icons get dirty or become illegible in some other way.
For this reason:
S Make sure all safety, warning and operational notices or instructions are always clearly legible.
S Clean or replace illegible safety, warning and Operating Instructions.
No trespassing
Areas designated in this manner may not be entered.
Electrical voltage
Only electricians may carry out work in working areas marked in this manner.
Unauthorized persons should not enter areas marked in this manner.
Hot surfaces
Hot surfaces, such as engines and hot liquids are not always perceptible. Do not touch
them without safety gloves.
Risk of life from suspended loads

During hoisting operations, loads may sway outwards and fall down. This may cause
severe injuries right up to death.
Follow the instructions

The instructions must be read and understood fully prior to any work being started.
The work may only be performed by personnel in accordance with the section on
personnel requirements.

2.12 Environmental protection
Danger of environmental pollution caused by improper handling of service products
Considerable damage is caused to the environment.
For this reason:
S Comply with the country-specific safety regulations.
S Use appropriate and suitably sized containers to collect service products.
S Store service products only in original containers.
S Use suitable binders to absorb leaking service products and dispose of the waste properly.
S If required, inform the municipal authorities in charge about the damage.
S Run cleaning fluid and rinse water through an oil separator with sludge trap.
The following substances harmful to the environment are being used:
Lubricants
Lubricants such as greases and oils contain toxic substances and other substances that are harmful to the
environment. They should not reach the environment. Disposal must be carried out by a professional
disposal company specialized in disposal.
Diesel fuel
Diesel fuel contains toxic substances that are harmful to the environment. It should not reach the
environment. Disposal must be carried out by a professional disposal company specialized in disposal.
Coolant
Coolants may contain toxic and other substances harmful to the environment. They should not reach the
DEF/AUS32/AdBlue ®
DEF/AUS32/AdBlue® contains substances that are harmful to water. They should not reach the


Engine type label
3 Engine type label
Always mention the engine type, engine number

and the factory number/order number in all
communications and queries.
For this reason, prior to initial start-up of the
engine, read the corresponding data from the
type label and enter it below.
The engine type labels (1) and (2) are fastened
on the crankcase.
Engine type (3)
......................................................................
Engine number (4)
......................................................................
Factory number/order number (5)
......................................................................

Engine type label
3.1 Explanation of engine no. (engine identification number)

Classification key 1 2 3 4
Engine no. XXX XXXX XXX XXXX
1 Type number according to the model code
2 Day of assembly (factory-internal specification)

3 Assembly sequence (sequential number on the day of assembly)
4 Production-related and equipment-specific information
3.2 Explanation of type designation

Model designation Explanation Example
D Fuel type Diesel
28 Indicator + 100 128 mm bore
6 Stroke indicator (rounded) 157 mm stroke
2 Number of cylinders 12 cylinders
L Turbocharging with turbocharging and intercooler
E Built-in engine Marine engine
4.. Type of use Marine engine
3.3 Information on the engine type label

For this reason, prior to commissioning of the engine, read the corresponding information from the engine
type labels and enter it on page 27.

Engine type label
3.4 Emission label
On engines with heat exchanger cooling system,

the emission label (1) is fastened to the expansion
tank.
On engines with externally mounted cooling
system, the emission label (2) is fastened to the
crankcase.
The required emission label has been placed on
this certified engine during the assembly process..

Engine type label
3.4.1 Duplicate emission label
If the emissions type plate is made illegible or it is

covered during the installation of the engine into
the system, thereby making it impossible to read
during routine maintenance, a duplicate type plate
must be attached to the system (see 40 CFR
1068.105(c)).
If necessary, MAN will supply the quantity of
replacement type plates. Send a written request
with the following information to MAN if you need
to attach a replacement type plate:
S Identification of the family (from the original
engine type label).
S The reason why you need a replacement type
plate for your model
S The number of replacement type plates needed
MAN will retain the following records for at least
eight years.
S Your written requests, documentation and
descriptions
S Number of replacement type plates sent
by MAN
→ All unused replacement type plates must be destroyed so that the intended use is no longer
possible.

Design and operation
4 Design and operation
4.1 Fields of application for the engines with aftertreatment system

The ship engines are suited for the propulsion of ships.
For the assignment of engine types to the approved operating modes, see Technical Data after page 95.
Typical application (examples)

Light duty: Yachts, patrol boats, marine rescue
Medium duty: Pilot vessels, passenger ships and ferries, patrol boats
Heavy duty: Trawlers, tugs, freight ships, ferries
4.2 Engine body and engine equipment

The engines are 12-cylinder 4-cycle diesel engines with exhaust gas turbocharging and intercooling.
Split crankcase, wet cylinder liners made of extremely wear-resistant special spin casting, steel pistons with
cooling channel for piston cooling. Single cylinder heads with shrink-fit valve seats and press-fit valve
guides. 4 valves per cylinder. Valve control provided by the central camshaft, roller tappets, push rods and
rocker arms (OHV).
Engine monitoring
Various sensors monitor the engine. The sensors are e.g. speed and temperature sensors, which send
information about various engine operating conditions and states to the engine control units. The engine
control units process the information received from the sensors and control the output signals which are
sent to the corresponding actuators. The actuators convert the signals into mechanical variables.
Injection system
High-pressure common rail injection system in conjunction with EDC17 (Electronic Diesel Control).
Fuel system
Low-pressure system consisting of fuel lines, the manual supply pump and the selectable fuel filters.
The high-pressure system consists of the flow-rate controlled high-pressure pumps with flange-mounted
fuel supply pumps and the pressure pipes with rail pressure sensor and pressure-limiting valve.
Engine lubrication
Force-feed lubrication for all bearing locations. 2 rotor oil pumps driven by the crankshaft.
2 oil modules consisting of an oil cooler, oil separator and oil pressure control valve.
Oil injection nozzles for piston cooling.
Classifiable engines are supplied with selectable, remote oil filters.
Cooling system
The engine is liquid-cooled. The cooling system is design as a closed overpressure system. The cooling
circuit is a thermostat-controlled forced circulation cooling system.
The maintenance-free coolant pump is mounted to the face of the engine and is driven using a gear set.
Elastomer elements dampen the transmission of crankshaft torsional vibrations.
Heat exchangers and intercoolers are cooled with sea water.
In addition to the heat exchanger cooling system, there is still a dual-circuit cooling system (externally
mounted cooling system)!

Intake and exhaust system

The intake air reaches the exhaust gas turbochargers via the air filters. The now-compressed charge air is
cooled while flowing through the intercooler before it is fed to the engine.
The exhaust manifolds are cooled by the engine coolant, The gear driven marine pump is attached to the
flywheel housing.
Flywheel housing and flywheel

The flywheel housing is designed with a connection according to SAE1.
Depending on the type of application, various flywheel designs are available, e.g., light or heavy flywheel.
Starter
The electric starter is designed as an insulated two-pole unit. The starter is attached on the right of the
engine; alternatively, the starter can also be omitted.
Alternator
An alternator isolated with double-poles (1 x 120 A or 2 x 120 A) is available upon request.
Aftertreatment system
The aftertreatment system is described in separate instructions.
4.3 Classification
With classified design:

For commercial use, ships are frequently subject to the regulations or a classification agency. The safety
standards of said classification agency must then be implemented during the construction and outfitting of
these ships.
These safety standards also refer to, among other things, the dimensioning, design and construction of the
machinery, so that
S failures due to overloading are avoided,
S risk of fire is reduced to a minimum,
S accidents involving personal injury during operation and maintenance are prevented.
The D2862 LE4xx engine is supplied in a classifiable design and is also subject to these regulations.
Therefore, classifiable engines are provided with specified safety equipment, e.g. selectable fuel and oil
filters, leak proof injection lines etc. from the factory.

4.4 Engine views D2862 LE4xx (1-stage turbocharged)
4.4.1 View from front right
(1) Switchable oil filter (4) Oil dipstick

(only with classified design) (5) Fuse box
(2) V-belt cover (6) Exhaust manifold (outlet)
(3) Seawater outlet (7) Switchable fuel filter
B1 Bank 1 (Cylinder 1 to 6, Master)

B2 Bank 2 (Cylinder 7 to 12, Slave)

4.4.2 View from rear left
(1) Air filter (3) Flywheel housing

(2) Flywheel (4) Elastic engine mount / engine feet

Transport, packaging and storing
5 Transport, packaging and storing

It is essential that the "Installation Instructions" be followed for installation and commissioning of a new or
overhauled engine.
Tip for users

Installation and commissioning to be carried out only by employees of the manufacturer of the complete
system or by persons authorized by him.
5.1 Requirements
Before starting the work, read and follow the general safety instructions and the safety instructions given in
this chapter.
material damage.
Personal protective equipment

The following protective equipment must be worn:
S Industrial protective clothing
S Hard hat
S Safety shoes
S Safety gloves
5.2 Safety instructions
Suspended loads
DANGER
Risk of life from handling transport goods incorrectly
For this reason:

S Have the engine transported only by trained personnel.
S Ensure that during transport, no persons, objects or obstacles are located in the swivel range of the
transport package.
S Move loads only under supervision.
S Use only approved lifting gear with adequate load-bearing capacity.
S Do not use any torn or chafed hoists such as cables and belts.
S Do not place hoists such as cables or belts on sharp edges and corners, do not put knots in them and
do not twist them.
S Use the lifting eyes only for transporting the engine without attachments.
S Pay attention to the markings and information about the center of gravity on the packages.
S While transporting with the crane, sling the crane hook in such a manner that it lies above the center
of gravity of the package.
S Lift the package carefully and observe whether it tilts. If necessary, change the slinging point.
S Handle transport packages carefully and pay attention to the icons and instructions on the packaging.
S Cables and chains must exert vertical tension (tolerance: 5°) on the crane hooks.
S Prohibit unauthorized transport or the placing/removing of transport aids.
S Do not step on the engine covers.
S Set the load down when leaving the workplace.

NOTICE
Risk of property damage from improper transport
Transport packages may fall or turn over as a result of improper transport.
For this reason:
S Proceed cautiously when off-loading the transport packages upon delivery as well as during transport
within the facility.
S Pay attention to the icons and instructions on the packaging.
S Use only approved lifting gear with adequate load-bearing capacity.
S Do not use any torn or chafed hoists such as cables and belts.
S Do not place hoists such as cables or belts on sharp edges and corners, do not put knots in them and
do not twist them.
S Use the lifting eyes only for transporting the engine without attachments.
S Pay attention to the markings and information about the center of gravity on the packages.
S While transporting with the crane, sling the crane hook in such a manner that it lies above the center
of gravity of the package.
S Lift the package carefully and observe whether it tilts. If necessary, change the slinging point.
S Cables and chains must exert vertical tension (tolerance: 5°) on the crane hooks.
S Set the load down when leaving the workplace.

5.3 Transport inspection

Check the delivery for completeness and transit damage on receipt.
Proceed as follows in case of externally identifiable transport damage:
S Do not accept the shipment or accept it conditionally.
S Note the scope of damage on the transport documents or on the packing slip of the carrier.
S Register a complaint.
Tip for users

File a complaint about each defect as soon as it is identified. Claims for compensation can be enforced
only within the applicable periods for registering complaints.
5.4 Packaging
About the packaging

The individual packages must be packed appropriately for the expected conditions of transport.
The packaging should protect the individual components from transport damage, corrosion and other types
of damage until the time of assembly / installation. Therefore, do not destroy the packaging, and remove it
only just prior to assembly / installation.
Handling packaging materials

Dispose of the packaging material in accordance with applicable statutory regulations and local regulations.
Improper disposal of packaging materials may endanger the environment
For this reason:
S Dispose of the packaging materials in an environmentally friendly manner.
S Observe and follow the local regulations for disposal. If necessary, hire a professional company for
disposal.
5.5 Storage
Storing the packages

Store the packages under the following conditions:
S Do not store them outdoors.
S Store them so that they are dry and dust-free.
S Do not expose them to corrosive media.
S Protect them from sunlight.
S Avoid mechanical vibrations.
S Storage temperature: 15 to 35 °C.
S Relative humidity max. 60%.
S For storage exceeding 3 months, check the general condition of all parts and the packaging.
If necessary, replenish or reapply the preserving agent.
Tip for users

In some cases, there are instructions on the packages for storage that go beyond the requirements
mentioned here. Comply with these accordingly.

5.6 Transport
5.6.1 Engine without transmission
Attachment points
(Principle representation of a reference engine)
There are 4 lifting eyes (1) mounted on the engine to lift it.
Use sufficiently dimensioned crane lifting gear to lift an engine!
Cables and chains must exert vertical tension (tolerance: 5_) on the crane hooks!

5.6.2 Engine with transmission
Attachment points
(Principle representation of a reference engine)
There are two lifting eyes on the transmission (4), and two on the engine (3) to lift the engine.
Use sufficiently dimensioned crane lifting gear (1) to lift an engine!
Cables and chains (2) must exert vertical tension (tolerance: 5_) on the crane hooks!

Transporting with the crane

The engine may be transported with a crane under the following conditions.
S The crane and lifting gear must be designed for the weight of the engine.
S The operator must be authorized to operate the crane.
► Attach cables, belts or multi-point suspension gear in accordance with the diagram.
► Ensure that the transport package is hanging straight and, if necessary, pay attention to the eccentric
center of gravity.
► Start transport.
Transporting with the forklift

The engine may be transported with a forklift under the following conditions.
S The forklift and hoisting gear must be designed for the weight of the engine.
S The engine must be fixed securely on the pallet.
S The forklift driver must be qualified and authorized to drive the forklift.
► Drive the forklift between or below the runners of the pallet.
► Drive the fork until it projects from the opposite side.
► Make sure that the pallet cannot tilt if the center of gravity is not in the middle.
► Lift the pallet with the transport package and begin transport.

Installation and commissioning
6 Installation and commissioning
6.1 Requirements
this chapter.
material damage.

S Safety shoes
S Safety gloves
Personnel
The commissioning (final acceptance) is performed using a commissioning record which can only be
carried out and signed off by an MAN-authorized employee.
NOTICE
Risk of damage to the engine due to improper installation / commissioning
For this reason:

S Install the components properly.
S Maintain the prescribed screw-tightening torque.
S Commissioning is done only by trained specialists.
S Secure components so that they do not fall down or turn over.
Basic rules
WARNING
Risk of injury from improper installation and commissioning
For this reason:
S Ensure adequate room for assembly before beginning the work.
S Proceed cautiously with exposed and sharp-edged components.
S Install the components properly.
S Maintain the prescribed screw-tightening torque.
S Secure components so that they do not fall down or turn over.
S Before commissioning the engine, read the instructions carefully and make sure that you are familiar
with the "critical" areas.
S For safety reasons, we recommend that the entry to the engine room be marked with an "No entry" sign
and that operating personnel be informed that they are responsible for the safety of individuals who
enter the engine room.

6.3 Installation of the engine

Installation of the engine, i. e. connecting the energy source or connecting the cooling system, must be
carried in accordance with information from the manufacturer of the overall system and with the aid of the
respective installation instructions.
6.3.1 Interfaces between the engine and system

During installation of the engine, the following installation work needs to be carried out on the interfaces
between the engine and the system:
(1) Attach the exhaust system, see page 59
(2) Connect the attached or remote oil filter (only with classified design), see page 47
(3) Connect sea water outlet, see page 51
(4) Installation of elastic engine mounts, see page 46
(5) Attach hydraulic pump on PTO, see page 62
(6) Connect fuel system, see page 54
(7) Attach coupling/transmission, see page 44
(8) Connect seawater inlet, see page 51
Installation instructions for modular aftertreatment system, see “Modular aftertreatment system, marine”.
6.3.2 Installation drawing
Tip for users

The basis for installing the engine are the installation instructions and installation drawing
6.3.3 Bolted connections
NOTICE
Risk of material damage from improperly tightened bolted connections
For this reason:

S Use an impact screwdriver with max. 50 % of the specified final torque.
S The final tightening must always be done with a torque wrench.
Torques for bolted connections, see page 68.

6.4 Completing the engine and assembling the unit
6.4.1 Attaching a transmission to the flywheel housing
Flywheel
The connecting dimensions of the flywheel (1) are

specified in the installation drawing.
S Remove oil, grease and preserving agents from
the flywheel.
Flywheel housing
The installation drawing provides information about

the dimensions of the flywheel housing (1) and the
type of bolted connections for attaching it to the
transmission.

6.4.2 Checking the axial clearance of the crankshaft
NOTICE
Danger of engine damage from couplings and attachments
For this reason:

S The structurally specified axial clearance of the crankshaft of the engines must not be reduced.
S Check the axial clearance of the crankshaft.
Special tools
[1] Dial gage bracket 08.71082-0005

S Check the crankshaft axial play with:
S Dial gage [2]
[2] Dial gage 08.71000-3217

S Check the crankshaft axial play with:
S Dial gage bracket [1]
Measure the axial clearance of the crankshaft before and after flange-mounting attachments to the engine.
► Remove V-belt guard

► Place the gage holder (1) [1] incl. dial gage (2)
[2] on the engine so that the pin of the dial gage
rests on the vibration damper under pre-load
► Press the crankshaft in the axial direction
toward the flywheel housing until the stop
► Set the dial gage (2) to zero
► Pull the crankshaft in the axial direction away
from the flywheel housing until it stops
► Read the value displayed on the dial gage (2)
Axial clearance of the
crankshaft: . . . . . . . . . . . . . . . . 0,20 - 0,40 mm
If the results of the measurement are outside of
tolerance or if the crankshaft springs back after
being moved, check attachment.

6.5 System installation in the ship
6.5.1 Installing elastic engine mounts

The maximum adjustable height of all mounts is 10 mm. This height cannot be exceeded. Compensate for
larger differences in height by using backing plates.
The less the adjustment height can be adjusted, the more spare height is available for subsequent
readjustments. The drive system must be adjusted prior to commissioning, see the engine installation
instructions.
Marking the mounts

The elastic mounts are available from MAN.
Refer to the layout drawings for the dimensions of
the mount and the drilling pattern. This is available
with MAN, see page 2 for the contact address.
(1) Mounting bolts M 20, strength class 8.8
(2) Bolts of the transport lock
(3) Height adjustment
(4) Mounting bolt for engine base, M 20
S Place the drive system with elastic mounts on
the engine foundation. Pay attention to the
correct arrangement of the mounts (Shore
hardness).
S Fasten the engine bases and the transmission
bases together using the elastic mounts.
Arrangement of elastic engine mounts

Engine type MAN part number Shore hardness
D2862 LE496 / LE459 / LE489 51.96210-7050 70
D2862 LE428 / LE438 / LE469 / LE427 / LE437 / LE447 51.96210-7051 65
D2868 LE466 (V8) 51.96210-7052 60
Elastic mounts for flanged integral V-transmission
(1) Mounting bolt for transmission base, M 20

(2) Height adjustment
(3) Screws of the transport lock
(4) Mounting bolts M 20, strength class 8.8
Arrangement of elastic engine mounts

Engine type MAN part number Shore hardness
D2868 LE466 (V8) 50.96210-7000 55

6.6 Connecting the oil filter (Version 1)

Classified engines must be equipped with selectable oil filters.
Depending on the version, the selectable oil filter supplied by MAN is installed on the engine or is remote.
The oil filter is connected to the engine via hose lines. With regard to operating pressure, fire resistance
and material selection, the hose lines supplied by MAN are designed for hot engine oil. The connections
must not be mixed up during installation.
(1) Selector lever (4) Pressure release screw

(2) Oil drain valve (2x) (5) Collector piece for external oil filter
(3) Oil filter cover
IN: polluted oil inlet
OUT: clean oil outlet
Version 2, see page 49

6.6.1 Assembling the oil filter

The selectable oil filter supplied by MAN is not installed on the engine and must be positioned near the
engine in the engine room on a side wall, at the same level as the engine foundation
The dismantling height of the filter element is

220 mm.
The selector lever and the drain plugs must be
easily accessible.
Hole pattern oil filter:
Dimension A . . . . . . . . . . . . . . . . 260 +/-0,4 mm
Dimension B . . . . . . . . . . . . . . . . 70 +/-0,4 mm
Dimension C . . . . . . . . . . . . . . . 106 +/-0,4 mm
Dimension D . . . . . . . . . . . . . . . 30 +/-0,4 mm
Through hole . . . . . . . . . . . . . . . Ø 13 mm (1x)
Threaded hole . . . . . . . . . . . . . . M12 (4x)
Thread depth . . . . . . . . . . . . . . . 18 mm (4x)
6.6.2 Connecting the hose lines
Depending on the installation conditions, hose

lines are available with lengths of either 800 mm
or 2,000 mm.
The minimum bending radius is 340 mm.
S Connect hose lines from the oil filter (1).
S Connect hose lines to oil filter (2).
Threaded connections of all connections M52x2
6.6.3 Sealing connection points
Seal the marked connections (X) with the attached

sealing tape (04.93300-9282) as spray protection
after the assembly of the oil-filter and the hoses.

6.7 Connecting the oil filter (Version 2)

Classified engines must be equipped with selectable oil filters. The selectable oil filter supplied by MAN is
not installed on the engine and must be positioned near the engine, at the same level of the engine
foundation in the engine room.
The oil filter is connected to the engine via hose lines. With regard to operating pressure, fire resistance
and material selection, the hose lines supplied by MAN are designed for hot engine oil. The connection
must not be mixed up during installation.
(1) Feed to oil filter (contaminated oil) (6) Drain plug

(2) Return from oil filter (clean oil) (7) Pressure equalization valve lever
(3) Hose line from oil filter (clean oil) (8) Filter housing
(4) Selector lever (9) Ventilation screws
(5) Oil collection pan (10) Hose line to oil filter (contaminated oil)

6.7.1 Assembling the oil filter
The dismantling height of the filter element is

530 mm.
The selector lever (1) must be easily accessible
and able to move freely.
The drain plugs (3) (one per filter housing) must be
easily accessible.
Installation drawing, see Installation Instructions.
S Position oil filter on a stable foundation (2).
6.7.2 Required space for oil lines
Depending on the installation conditions,

hose lines are available with lengths of either
800 mm or 2,000 mm.
The minimum bending radius is 340 mm.
S Connect hose lines from oil filter (1).
S Connect hose lines to oil filter (2).
Seal the marked connections with the attached sealing tape (04.93300-9282) as spray protection after the
assembly of the oil-filter and the hoses, see page 48.

6.8 Connecting the cooling system
6.8.1 Connecting the sea water lines for engine cooling (engines without
externally mounted cooling system)
The installation drawing provides information about

the design of the sea water connections.
S Connect the seawater inlet (1) (swivels by 90°)
S Connect the sea water outlet (2)

6.8.2 Connecting the sea water lines for engine cooling (engines with externally
mounted cooling system)
Connections on engine for high-temperature circuit
(1) Engine outlet to cooling system

(2) Engine inlet from cooling system
(3) Filling pipe from expansion tank to coolant
pump of high-temperature circuit
(4) Breather pipe from engine to expansion tank
Connection acc. to diagrams Hose connection acc. Internal ∅ External ∅

to factory standard mm mm
(1) Engine outlet to cooling system M3103-2 60 70
(2) Engine inlet from cooling system M3103-2 60 70
(3) Filling pipe from expansion tank to coolant M3101-3 19 25
pump of high-temperature circuit, DN25
(4) Breather pipe from engine to expansion tank, M3101-1 7 10
10x1.5
The connecting pieces (1), (3) and (5) can be
attached on either the left or right of the engine.
(1) Adapter for engine outlet to cooling system,
attached on the left
(2) Alternative attachment on the right
(3) Adapter for filling pipe from expansion tank,
attached on the right
(4) Alternative attachment on the left
(5) Adapter for engine inlet from cooling system,
attached on the left
(6) Alternative attachment on the right

Connections on engine for low-temperature circuit
(1) Breather pipe from the intercooler to

expansion tank
(2) Coolant outlet to cooling system
(3) Filling pipe from expansion tank to coolant
pump of low-temperature circuit
(4) Coolant inlet from cooling system
Connection acc. to diagrams Hose connection acc. Internal ∅ External ∅

to factory standard mm mm
(1) Breather pipe from engine to expansion tank, M3103-3 7 10
DN10
(2) Coolant outlet to cooling system M3103 61 65
(3) Filling pipe from expansion tank to coolant 9 15
pump of low-temperature circuit
(4) Coolant inlet from cooling system M3101-2 65 75

Cable harness for MAN expansion tank
Position 1, 2 and 3 are supplied separately.

(1) MAN expansion tank
(2) Coolant level sensor
(3) Cable harness adapter (length 5,5 m)
(4) Connection engine cable harness
Plugs (X) are not used.
6.9 Connecting the fuel system
6.9.1 Connecting the fuel lines
(1) Connecting the fuel supply (M30x2)

(2) Connecting the fuel return (M30x2)
Length: 1500 mm

6.9.2 Installing fuel pre-filter and hand pump - classified engines

Fuel pre-filter and hand pump for non classified engines, see page 57
NOTICE
Risk of property damage due to dirt particles
Risk of components getting damaged by impurities in the fuel system
For this reason:
S Be sure to maintain the utmost cleanliness when working on the fuel system.
Installing fuel pre-filter and hand pump
The fuel pre-filter with water separator should not be

attached directly to the engine since the engine
vibrations may degrade the water separation.
Hole pattern fuel pre-filter:
Dimension X . . . . . . . . . . . . . . . . 124 mm
Dimension Y . . . . . . . . . . . . . . . . 390 mm
Dimension Z . . . . . . . . . . . . . . . . 9 mm
Mounting bolts: Hex screws or cylinder screws,
each with washers
(1) M8x30 (2x)
(2) M8x50 (2x)
(3) Spacer bush:
internal diameter . . . . . . . . . . . . Ø 9 mm
External diameter . . . . . . . . . . . Ø 18 mm
Length . . . . . . . . . . . . . . . . . . . . . 35 mm
Hole pattern hand pump:

Dimension A . . . . . . . . . . . . . . . . 17 mm
Dimension B . . . . . . . . . . . . . . . . 46 mm
Bore C . . . . . . . . . . . . . . . . . . . . 8.5 mm
Mounting bolts M8x60 (4x)

Installing fuel pre-filter and hand pump
NOTE
The fuel pre-filter is only classifiable with
protective plate
Therefore:
S Install protective plate on the fuel pre-filter.
The protective plate (X) must be installed by

the shipyard.
(1) Selector lever
(2) Fuel inlet (from tank to filter)
(3) Fuel outlet from filter (to inlet (6) hand pump)
(4) Filter cartridge
(5) Water drain plug / water level sensor
(connection: cable harness for fuel pre-filter)
(6) Fuel inlet (from filter)
(7) Fuel outlet (to engine)
Bolted connections for fuel pre-filter:
Connection (2):
- sealing ring (for M18)
- socket (M18x1.5/M22x1.5)
Connection (3):
- socket (M18x1.5/M22x1.5)
Bolted connections for hand pump:
Connection (6):
- socket (M18x1.5/M22x1.5)
Connection (7):
- socket (M18x1.5/M22x1.5)
Lever position (1) for fuel pre-filter and hand pump, see page 84

6.9.3 Installing fuel pre-filter and hand pump - non classified engines
Fuel pre-filter and hand pump for classified engines, see page 55
NOTE
There is the risk of damage to property caused by dirt particles
Risk of components getting damaged by impurities in the fuel system
Therefore:
S Pay attention to utmost cleanliness when working on the fuel system.
Mount the fuel pre-filter
The fuel pre-filter with water separator should not

be attached directly to the engine since the engine
vibrations may degrade the water separation.
Sufficient space must be available to trap the
water separated and to change the filter cartridge
(H approx. 200 mm).
Hole pattern fuel pre-filter:
Dimension X . . . . . . . . . . . . . . . . 65 mm
Bore (3x) . . . . . . . . . . . . . . . . . . . Ø 9 mm

Connect the fuel pre-filter and hand pump
Each choose a connection at position (1), (2)

and (3).
Opposite side must be closed.
(1) Fuel inlet (from tank to filter)
(2) Fuel outlet from filter (to inlet (6) hand pump)
(3) Fuel outlet (to the engine)
(4) Filter cartridge
(5) Water drain plug / water level sensor
(connection: cable harness for fuel pre-filter)
(6) Fuel inlet (from filter)
Fittings for prefilter:

Choose connection (1):
Sealing ring (for M18)
Fitting (M18x1,5/M30x2)
Opposite side must be closed (Screw plug
M18x1,5).
Fittings for hand pump:

Adapter fitting (M18x1,5/M22x1,5)
Opposite side:
Screw plug (M18x1,5)
Connection (6):

6.10 Attaching the exhaust system
6.10.1 Exhaust gas outlet at engine
Single-stage turbocharging
Engines with single-stage turbocharging are

equipped with one exhaust manifold per bank
of cylinders.
The exhaust manifolds can be supplied with a
choice of the outlet upwards (1) or to the rear (2).
These exhaust manifolds are not cooled by engine
coolant.
Therefore, these manifolds must be insulated to
maintain the max. permissible surface temperature
of no more than 220 °C.
Two-stage turbocharging
Engines with two-stage turbocharging are fitted

with a combined exhaust manifold.
The exhaust manifold can be fitted either to the
rear (1) or upwards (2).
A twin-flow exhaust gas outlet (3) is supplied

loose.
(Principle representation)

6.10.2 Connecting the exhaust system to the engine
Between the engine and the exhaust system,

elastic connecting elements must be installed
which permit engine movements allowed by the
elastic engine mounts and decouple the engine
vibrations from the exhaust system.
Example: Compensator (1)
Installing exhaust-gas compensator under tensile
pre-stress, see Installation Instructions.
NOTICE
Component damage by the action of force on the turbocharger.
For this reason:
S Exhaust gas lines must be mounted in such a manner that no forces act on the turbocharger.

6.11 Connecting the cabin heating

For information on thermal output and diagram, see engine installation instructions.
Heating return on expansion tank
(1) Pipe 18x1.5, internal diameter 15 mm

(2) Screwed connection M26x1.5
(3) Screw plug M26X1.5
Heating feed on exhaust manifold
(1) Pipe 18x1.5, internal diameter 15 mm

(2) Screwed connection M26x1.5
(3) Screw plug M26X1.5
Heater feed (two-stage charging)
(1) Pipe 18x1.5, inside diameter 15 mm

(2) Screw plug M26x1.5
(3) Screw terminal M26x1.5

6.12 PTO/hydraulic pump
The engines can be equipped with a PTO on the

flywheel housing to the rear right of the engine.
A hydraulic pump (1) can be attached there.
If a hydraulic pump is not fitted by the factory,

the PTO is closed off by a blind flange (2).
PTO data for V-engines:

Direction of rotation Left
viewed on flywheel
Engine speed 1.3 x engine speed
Max. transmittable 180 Nm
torque
The power is transmitted via a coupling sleeve (3)

with internal gearing.

6.13 Connecting the electrical system
NOTICE
Component damage due to corrosion
For this reason:
S The negative lead of the starter battery must be routed back to starter terminal 31.
S Connect the engine and all pipe connections from and to the engine by "earthing cable" with the ship
potential.
In dual engine systems, independent wiring is necessary for each engine, i.e. the circuits of the engines
should not be combined with one another.
Batteries
For each engine there must be separate batteries provided for the starter. On-board 24 V DC consumers
must be supplied with separate batteries.
6.13.1 Starter
The starter is designed with two poles on all MAN

marine engines. Therefore the positive lead of the
starter battery must be connected to terminal 30 of
the starter (2), and the negative lead of the starter
battery must be connected to terminal 31 of the
starter (3).
The starter can only be mounted on the right side
of the engine.
The negative lead should never be connected to
the ship potential, the ship's rear section or other
components.
Connection dimensions, terminals 50 and 85 (1)
Connection thread: . . . . . . . . . . . . . . . . . . . . . . M6x1
Tightening torque: . . . . . . . . . . . . . . . . . . . . . 3-5 Nm
Connection dimensions, terminal 30 (2)
Connection thread: . . . . . . . . . . . . . . . . . . M12x1,75
Tightening torque: . . . . . . . . . . . . . . . . . . . 20-30 Nm
Connection dimensions, terminal 31 (3)
Connection thread: . . . . . . . . . . . . . . . . . . M12x1,75
Tightening torque: . . . . . . . . . . . . . . . . . . . 20-30 Nm
Match battery capacity, cable length and cable
cross-sectional area to one another.
Starter type Mitsubishi Electric Corporation

Nominal voltage: V 24
Rated power: kW 7

6.13.2 Alternators
One alternator (1) each is available to charge the

starter batteries of each engine.
The alternator is completely wired ex-factory.
This alternator should not be used to charge
batteries which are used to supply additional
consumers.
However, if batteries used for supplying other
consumers need to be charged, a second
alternator (2) (optional) can be installed.
Both alternators are designed as insulated
two-pole units. To ensure potential-free wiring,
the entire arrangement of the alternators on the
engine is insulated. This is why the housing of the
alternators is connected to the minus pole of the
associated battery (3).
Alternator type Bosch (LEB10)

Nominal voltage: 28 V
Rated current 120 A
Tightening torque values for three-phase alternator in Nm

Mounting nut M8, terminal B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 + 2 Nm

6.14 Attaching the protective device
WARNING
Risk of life due to inadequate protective devices
The V-belt cover included in the scope of supply is not a protective device.
For this reason:
S Implement suitable protective devices before putting the engine into operation.
S Supplied V-belt cover (1).

S Use only appropriate protective device.

6.15 Plugs on engine
NOTICE
Therefore:
S For vibration decoupling, connecting cables must be attached to the engine or gearbox at a distance
of approx. 150 mm
Interface Engine -
Electronic box (E-Box)

►(1) X50
►(2) X1
For further information, see
Operating Instructions „MAN Intelligent Marine
Safeguard System“
Fuel prefilter with water separator

►(1) X35
Transmission
►(2) X33
►(3) X3
►(4) X32
Aftertreatment system
►(5) X61 Master
►(6) X62 Slave
Cylinder bank Master/Slave, see page 33
Commissioning/ Service interface
►(7) X30

In addition, for classified engines:
NOTICE
Therefore:
S For vibration decoupling, connecting cables must be attached to the engine or gearbox at a distance
of approx. 150 mm
Voltage supply on fuse box

The power supply from the customer battery (1)
does not run via the starter, but it is fed directly to
the fuse box (3). Before that, the supresserdiode
(2) is installed.
Voltage supply EDC/AL-System

►X104.1
Voltage supply SU-System
►X104.6

6.16 Torque values for screw connections according to the M 3059 factory
standard
Bolts/nuts with outer hex or inner hex, head without collar or flange
Thread size Strength classes / Tightening torque values in Nm

x pitch
for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M4 2.5 4.0 4.5
M5 5.0 8.0 9.0
M6 9.0 13.0 15.0
M7 14.0 20.0 25.0
M8 22.0 30.0 35.0
M8x1 23.0 35.0 40.0
M10 45.0 65.0 75.0
M10x1.25 45.0 67.0 75.0
M10x1 50.0 70.0 85.0
M12 75.0 110.0 125.0
M12x1.5 75.0 115.0 130.0
M12x1.25 80.0 120.0 135.0
M14 115.0 175.0 200.0
M14x1.5 125.0 185.0 215.0
M16 180.0 265.0 310.0
M16x1.5 190.0 280.0 330.0
M18 260.0 365.0 430.0
M18x2 270.0 385.0 450.0
M18x1.5 290.0 405.0 480.0
M20 360.0 515.0 600.0
M20x2 380.0 540.0 630.0
M20x1.5 400.0 565.0 670.0
M22 490.0 700.0 820.0
M22x2 510.0 725.0 860.0
M22x1.5 540.0 750.0 900.0
M24 620.0 890.0 1040.0
M24x2 680.0 960.0 1130.0
M24x1.5 740.0 1030.0 1220.0

Bolts / nuts with outer hex or inner hex, head with collar or flange
Thread size Strength classes / Tightening torque values in Nm

x pitch
for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M5 6.0 9.0 9.9
M6 10.0 15.0 17.0
M8 24.0 35.0 41.0
M8x1 25.5 40.0 43.7
M10 44.5 65.0 75.9
M10x1.25 46.5 70.0 79.7
M10x1 48.6 75.0 83.5
M12 81.5 120.0 140.0
M12x1.5 85.0 125.0 146.0
M12x1.25 88.5 130.0 152.0
M14 128.0 190.0 221.0
M14x1.5 138.0 200.0 237.0
M16 200.0 285.0 334.0
M16x1.5 212.0 300.0 354.0
M18 279.0 395.0 464.0
M18x2 294.0 420.0 489.0
M18x1.5 309.0 440.0 515.0
M20 382.0 545.0 637.0
M20x2 400.0 570.0 667.0
M20x1.5 418.0 595.0 696.0
M22x2 558.0 795.0 930.0
M22x1.5 580.0 825.0 966.0

Installation torques for hollow screws and screw-in fittings, Screw plugs, hose fittings, and
screw-in fittings with cutting ring union
SPermitted for bolted connections with Cu and BS sealing rings
SPermitted for bolted connections in aluminum female thread
SPermitted also for components with steel outside thread - materials according to DIN 3859-1
SImpact screws are not permitted for installation
SComponents that are much weaker when compared with standard parts must be evaluated separately
Applicable to: Applicable to:

-hollow screws (DIN 7643 or similar) screw-in fittings (DIN 3901, MAN 200
-screw-in fittings (DIN 3901/MAN 200 or similar for cutting ring union of a
or similar for cutting ring union of a continuing pipe line
continuing pipe line *)
-threaded plugs with inner and outer
hex (DIN 908, DIN 910/DIN 7604 or When tightening or undoing the cutting
similar) ring union, the respective part cannot
-hose clamps and fittings for plug be held in place.
connectors.
Thread size
x pitch
M8X1 11 Nm 21 Nm
M10X1 21 Nm 32 Nm
M12X1.5 32 Nm 42 Nm
M14X1.5 42 Nm 70 Nm
M16x1.5 52 Nm 130 Nm
M18X1.5 65 Nm 130 Nm
M20X1.5 75 Nm 190 Nm
M22X1.5 85 Nm 190 Nm
M24X1.5 95 Nm 190 Nm
M26X1.5 105 Nm 190 Nm
M27X2 105 Nm ----
M28 x 1.5 105 Nm 262 Nm
M30X1.5 125 Nm ----
M32X1.5 125 Nm ----
M33X2 125 Nm ----
*) tighten the cutting ring union

Applicable to: Applicable to:

-hollow screws (DIN 7643 or similar.) screw-in fittings (DIN 3901, MAN 200
-screw-in fittings (DIN 3901/MAN 200 or similar for cutting ring union of a
or similar for cutting ring union of a continuing pipe line
continuing pipe line *)
-threaded plugs with inside and
outside hexagon (DIN 908, DIN When tightening or undoing the
910/DIN 7604 or similar.) cutting ring union, the respective part
-hose clamps and fittings for plug cannot be held in place.
connectors.
Thread size
x pitch
M36X1.5 157 Nm ----

M38X1.5 157 Nm ----
M42X1.5 190 Nm ----
M45X1.5 190 Nm ----
M48X1.5 190 Nm ----
*) tighten the cutting ring union
Tip for users

When tightening or undoing the cutting ring
union, the respective part can be held in place.

6.17 Initial start-up

Proper initial commissioning is of critical significance for the operational safety and reliability of
the engines. If the commissioning is performed incorrectly, the immediate consequence is damage
to the engine.
Carrying it out consists of several steps:
S Thorough checking of the installation
S Fill with approved diesel fuel and vent the fuel system
S Fill with DEF/AdBlue®/AUS32
S Filling the engine with coolant, venting the cooling system
S Starting the engine
S Conducting a test drive, measuring and archiving important data
Carrying out the initial commissioning requires both special knowledge on the part of the
personnel and special equipment.
This is why the initial commissioning may only be carried out by persons or workshops that have been
authorized and certified by MAN Nuremberg (Marine engines department).
NOTICE
Initial start-up that has not been carried out properly can result in operational faults that cause
irreparable damage to the engine
For this reason:
S Commissioning is carried out only by authorized personnel of MAN Nuremberg (Marine engines
department).
S The commissioning is performed using a commissioning record sheet.
DANGER
Risk of life from non-functional safety equipment and devices
For this reason:
S Before beginning work, check whether all safety equipment is functional and correctly installed.
S Prior to starting the engine, check whether all safety equipment is functional and correctly installed.
NOTICE
JP8 diesel fuel and biodiesel may damage the engine and aftertreatment system
For this reason:

S Use only ultra low sulfur diesel fuel (#2 pump grade), which is compliant with ASTM D975 or EN 590
as well as the use of commercially available ULSD (specification of 15ppm max. sulfur fuel per US
Tier 4 is required).
S In case of damage, consult MAN or your MAN dealer for further direction.
S Use only DEF/AdBlue®/AUS32 according to ISO 22241 or DIN 70070.
S Additional information can be found in the MAN service product recommendations.
Tip for users

Use only service products that meet MAN regulations; otherwise, the liability for material defects is
rendered void!
https://ws-public.man-mn.com/portal/irj/asp

6.17.1 Filling with DEF/AdBlue®/AUS32
HINWEIS
Risk of damage to property by cleaning agents or fuel
The engine and aftertreatment system are damaged.
For this reason:
S Do not use to dirty containers or funnels to fill/top up DEF/AdBlue®/AUS32.
S When filling/topping up DEF/AdBlue®/AUS32, only use refilling containers.
S If fuels gets into the DEF/AdBlue®/AUS32 tank, do not start the engine.
S Keep the DEF/AdBlue®/AUS32 tank and DEF/AdBlue®/AUS32 line system free of cleaning agents
and fuel.
Before initial start-up, fill the DEF/AdBlue®/AUS32 tank.
Risk of damage to the environment due to incorrect storage
Do not allow DEF/AdBlue®/AUS32 to escape into the waste water or soil.
For this reason:
S Storage temperature: max. 25 °C
S Absorb leaked or spilled DEF/AdBlue®/AUS32 using binding agent and dispose of it properly.
S Store DEF/AdBlue®/AUS32 only in the original containers.
Do not allow service products to escape into the waste water or soil.
For this reason:
S Do not spill any service products when filling.
6.17.2 Filling with diesel fuel
DANGER
Risk of fire from diesel fuel
For this reason:

S During refueling, do not smoke in the hazard zone.
S Using open flames and sources of ignition is forbidden in the hazard zone.
S Fill up the tank only when the engine in switched off.
S Pay attention to cleanliness.
S Do not spill any diesel fuel.
For this reason:
6.17.3 Bleeding the fuel system

Bleed the fuel system prior to initial start-up. This procedure is described in the maintenance instructions.

6.17.4 Filling with coolant
For this reason:
The engine cooling system should be filled with a mixture of potable water and antifreeze based on
ethylene glycol or anti-corrosion agent.
For coolant capacity, see "Technical Data".
S Add coolant in accordance with the information provided by the manufacturer of the overall system.
S Fill coolant slowly (max. 10 l/min).
6.17.5 Leakage check of the entire cooling system

Check the cooling system for leaks prior to initial start-up. This procedure is described in the maintenance
instructions.

Control and operation
7 Control and operation
7.1 Requirements
this chapter.
material damage.

S Safety shoes
S Safety gloves
Personnel
The engine should be controlled and operated only by instructed persons or by trained specialists.
Basic rules
WARNING
Danger due to incorrect operation
Improper operation leads to severe personal injuries or damage to property.
For this reason:
S Before beginning work, ensure that all covers and protective devices are functional and have been
installed correctly.

7.3 Preparations prior to operation
NOTICE
Risk of engine damage from incorrect inspections
For this reason:

S Before each operation, perform a visual inspection and check the engine for damage or leaks.
S Do not operate the engine if it is damaged.
S Rectify minor faults immediately.
Tip for users

Use only service products that meet MAN regulations, otherwise, the liability for material defects is
rendered void!
For basic information on the service products, refer to the publication "Service products for MAN
industrial and marine diesel engines".
You can find approved products on the Internet at:
The basic requirement for trouble-free operation is to provide service products that have been approved
by MAN.
Check the fuel supply, coolant level and oil level prior to operation every time.
If required, top up diesel fuel, coolant, oil and DEF/AdBlue®/AUS32.
7.3.1 Checking the fuel supply and topping it up
DANGER
Risk of fire from diesel fuel
Diesel fuel is easily inflammable.
For this reason:
S During refueling, do not smoke in the hazard zone.
S Using open flames and sources of ignition is forbidden in the hazard zone.
S Fill up the tank only when the engine in switched off.
S Pay attention to cleanliness.
S Do not spill any diesel fuel.
Do not allow service products to escape into the soil, ponds, lakes and the like.
For this reason:
S Do not spill any service products when topping up.
1. Check the fuel supply and top it up, if required, according to the information provided by the
manufacturer of the complete system.
2. Open the shut-off valves in the fuel supply.

7.3.2 Checking DEF/AdBlue®/AUS32 and topping it up
HINWEIS
Risk of damage to property by cleaning agents or fuel
The engine and aftertreatment system are damaged.
For this reason:
S Do not use to dirty containers or funnels to fill/top up DEF/AdBlue®/AUS32.
S When filling/topping up DEF/AdBlue®/AUS32, only use refilling containers.
S If fuels gets into the DEF/AdBlue®/AUS32 tank, do not start the engine.
S Keep the DEF/AdBlue®/AUS32 tank and DEF/AdBlue®/AUS32 line system free of cleaning agents
and fuel.
For this reason:
Tip for users

Check the liquid level against the value specified by the manufacturer of the overall system and top up if
necessary.

7.3.3 Checking the coolant level
CAUTION
Risk of scalding by hot service products
For this reason:

S Check the coolant level only when the engine has cooled down.
NOTICE
Risk of engine damage from improper antifreeze
For this reason:

S Use only appropriate antifreeze.
For this reason:
The engine cooling system should be filled with a mixture of potable water and antifreeze based on
ethylene glycol or anti-corrosion agent.
Check the coolant level only when the engine has

cooled down.
► In the coolant level sight glass (1), the coolant
level must lie between "MIN" and "MAX" in the
coolant expansion tank.

Topping up the coolant
NOTICE
Risk of engine damage from temperature differences
For this reason:

S Do not fill cold coolant into a hot engine.
CAUTION
Risk of injury from hot liquids
The coolant reaches high temperatures during operation and causes scalding upon contact.
For this reason:
S Undo the cap cautiously with the safety valve.
S Release the pressure.
S Open the cover cautiously.
Tip for users

Use only service products that meet MAN regulations; otherwise, the liability for material defects is
rendered void!
For more information, see the MAN service product database.
Refill coolant only when the engine has cooled

down.
► If, under exceptional circumstances the
coolant level needs to be checked when the
engine is at operating temperature, turn the
cap (1) carefully to the pre-latching position -
relieve the pressure - and then open it carefully.
► Do not fill in any cold coolant in an engine at
operating temperature while topping up.
► Make sure that the "water - antifreeze" mixing
ratio is restored.
► The engine cooling system should be filled with
a mixture of potable water and antifreeze based
on ethylene glycol or anti-corrosion agent.
► Screw on the cap (1) hand-tight.
Caps that have been tightened forcefully can
no longer be opened!

Opening the cooling system when the engine is at operating temperature
If the cooling system is opened when the engine is

at operating temperature, then the pressure drops
in the cooling system.
In order to continue operating the engine without
the alarm after the cap has been opened, a system
pressure of 0.7 bar must be present in the cooling
system.
In order to achieve this, a pressure valve (1)
is installed on the expansion tank to which
a commercially available air pump may be
connected. The system pressure must be raised
to 0.7 bar with this pump.

7.3.4 Checking the engine oil level
Tip for users

Check the oil level when the engine is in a horizontal position and only about 5 minutes after it has been
shut down.
NOTICE
Risk of engine damage from incorrect oil
level
For this reason:

S Never fill in more than the quantity of oil
specified.
S Pay attention to the Min/Max marking on the
oil dipstick.
S Check the oil level and correct if necessary.
► Pull out the oil dipstick (1).

► Wipe off the oil dipstick (1) with a clean lint-free
cloth.
► Re-insert the oil dipstick (1) as far as possible.
► Pull out the oil dipstick (1) again and check the
oil level.
The oil level should be between the two notches
stamped on the dipstick and must never be below
the lower notch.
► Re-insert the oil dipstick (1) as far as possible.
► If necessary, top up the oil. MAX
► Do not overfill.
MIN

7.3.5 Topping up the engine oil
Do not allow service products to escape into the soil, ponds, lakes and the like.
For this reason:
S Do not spill any service products when topping up.
NOTICE
Risk of engine damage from incorrect oil
level
For this reason:

S Never fill in more than the quantity of oil
specified.
S Pay attention to the Min/Max marking on the MAX
oil dipstick.
S Check the oil level and correct it if necessary. MIN
► Unscrew the cap (1).

► Slowly fill engine oil via the filler neck.
The oil level should lie between the two notches
on the dipstick.
For oil capacity, see "Technical Data"
► Screw on the cap (1) again.
► Check the engine oil level

7.3.6 Checking the water trap on the fuel pre-filter

To protect the engine from dirt and water in the fuel, a fuel pre-filter with water separator is installed in the
fuel line from the tank to the engine.
NOTICE
Risk of engine damage from water and dirt in the fuel
For this reason:

S Depending on the incidence of water, service the fuel pre-filter regularly according to the
manufacturer's specifications.
Draining the water from the fuel pre-filter
► Remove protective plate (classified engines)

► Disconnecting the electrical connections
► Open the drain plugs (1),
- as required
- if monitoring system alarm appears
- during each engine oil change
► Allow the collected water to drain off into
a suitable container.
► Close the drain plugs (1).
► Install protective plate (classified engines)
(classified engines)
(non classified engines)

7.4 Switching the fuel pre-filter/fuel filter

Selectable filters are a requirement of the classification agencies
Switch levers are only available in the classified version.
Lever position:
1st Both filters in operation

(operating position)
2nd Right filter in operation
3rd Left filter in operation

7.5 Switching the oil filter
7.5.1 Version 1
Selectable filters are a requirement of the classification agencies
Switch levers are only available in the classified version.
NOTICE
Component damage from poor oil supply
For this reason:
S Do not leave selector leaver on center position.
1st Both filters in operation

(operating position)
2nd Right filter in operation
(Left filter is „CLOSED“)
3rd Left filter in operation
(Right filter is „CLOSED“)

7.5.2 Version 2
The oil filters of classified marine engines are designed as double filters. One filter unit is not in use during
operation and serves as a backup.
If necessary, it is possible to switch to the second filter unit with the aid of the switching mechanism.
The oil filter has a selector lever so that only one filter element at a time is in use.
S Selector lever in position (4), filter element (2) in use, filter element (5) not in use.
S Selector lever in position (3), filter element (5) in use, filter element (2) not in use.
(1) Pressure equalization valve, needed when changing the filter cartridges.
NOTICE
Selectable double filters are a requirement of the classification agencies
One filter element is in use, one filter element is not in use and serves as a backup.
For this reason:
S The selector lever must not be in the center position when the engine is operating.

7.6 Daily inspection before starting the engine

Visual inspections and functional checks to be done daily:
S Oil leakage
S Fuel leakages
S Coolant leakages
S Condition of the ribbed V-belt
S Loose or defective parts, loose screw connections
S Check filling level of the service products
When the engine is running:
S Unusual noises
S Smoke development
7.7 Starting and stopping the engine

For further information, see Operating Instructions „MAN Intelligent Marine Safeguard System“

7.8 Operating engine in ship mode
7.8.1 Operating ranges for ship engines

Relative load MMDS %
Engine speed in %
(1) Engine full load curve
Operating range
(2) Acceleration
S short-term operation to increase load by increasing speed
S Engine speed less than 100% of nominal speed
S Long-term operation for "heavy" is permitted
S Long-term operation for "medium" and "light" is not permitted
(3) Normal operation
S Long-term operation permitted, final speed 100 to 102% of nominal speed
(4) As-new condition
S Operating range with new fully laden ship
S Long-term operation permitted, final speed 102 to 104% of nominal speed
(5) Low load
S Operating range for relatively high speeds and low loads
S Long-term operation permitted, but inefficient

Maintenance and care
8 Maintenance and care
8.1 Maintenance Manual
NOTICE
Risk of engine damage due to improper maintenance
For this reason:

S Before carrying out maintenance work, read the maintenance instructions carefully.
S Carry out all maintenance work in accordance with the information in the associated documentation.
S Observe the service intervals.
S All components of the engine surroundings are to be included in the maintenance.
S Ensure adequate room for assembly before beginning the work.
Maintenance Manual
In addition to these operating instructions, there is a maintenance manual available for performing
maintenance on engines.
It contains a maintenance schedule and a description of maintenance work that is due at regular intervals.
Aftertreatment system maintenance instructions

In addition to these operating instructions, there is a maintenance instructions available for the modular
aftertreatment system for the maintenance of the aftertreatment system.
It contains a maintenance schedule and a description of maintenance work that is due at regular intervals.
Maintenance schedule
The maintenance schedule contains all maintenance work that needs to be done at regular intervals of time
or on reaching a certain number of operating hours.
Maintenance work
The maintenance instructions contains a brief description of the maintenance work.
8.2 Repair Manual

The repair manual contains a detailed description of all assembly and adjustment work on the engine. This
work should be carried out only by specialists who have been trained particularly for repair.

Faults
9 Faults
The engines are equipped with an intelligent marine monitoring system.
See Operating Instructions „MAN Intelligent Marine Safeguard System“
All important engine parameters are continuously recorded by sensors. This data is captured by the MAN
Monitoring and Diagnostic system and compared with stored target values.
In the event of a fault, the recorded engine parameters lie outside the permitted tolerance ranges and the
system initiates an alarm.
The MAN Monitoring and Diagnostic system can reduce the power output of the engine being monitored to
prevent consequential damage.
The MAN Monitoring an Diagnostic system can stop the monitored engine independently if the operation of
the machine is endangered by a technical defect.
To ensure the safety of the ship in hazardous circumstances, the override-system offers the possibility to
prevent the shutdown of the engine or the reduction of output, and to reactivate the full engine output.
Registered alarms are highlighted both visually and acoustically:
S On the color touch display at the operator´s stand and engine control room
S On the terminal box display (E-Box) in the engine room
NOTICE
Risk of engine damage
Alarms indicate technical faults which can result in consequential damage
For this reason:
S Arrange for the cause of a fault to be rectified immediately by MAN Service for marine engines.
A current directory of the service support locations can be found on the Internet at:
http://www.asp.mantruckandbus.com

Decommissioning and recommissioning
10 Decommissioning and recommissioning
10.1 Requirements
this chapter.
material damage.

S Safety shoes
S Safety gloves
Personnel
Only instructed technical professionals should decommission or recommission an engine.
Basic rules
WARNING
Risk of injury caused by untrained personnel
For this reason:
S Have the engine serviced and repaired only by trained personnel.
S Regular attendance at product and user training.

10.3 Taking the engine out of operation temporarily

Depending on the duration, temporary corrosion protection that meets MAN factory standard M 3069 is
required when taking an engine out of operation.
The factory standard is available from the customer service department at the Nuremberg factory.
Tip for users

Proper and careful restarting of new engines or those that have already been run has a great impact on
their operational safety and residual service life.
Basically, you must endeavor to preserve engines at the time of shutting them down or, in the case of
new engines, after the factory test run.
If the engine had not been preserved before being shut down, there is the danger of cylinder liners,
piston rings and valves getting corroded, especially if the intake air and exhaust gas openings have not
been closed and the engine has been stored outdoors.
Foreign substances, rainwater and the like that have entered sometimes require complete disassembly
of the engine.
10.3.1 Taking the engine out of operation for up to 3 months

Even simple measures prior to temporary shut-down of the engine provide effective protection against
corrosion:
S Clean the outside of the engine thoroughly with compressed air. Dry the engine surface.
S Fill the fuel tank with diesel fuel.
S For information on establishing the concentration of the antifreeze in the coolant and the prescribed
mixing ratio, refer to the publication "Service products for MAN industrial and marine diesel engines".
S Close all engine openings (for intake air and exhaust gas) so that no air exchange can take place with
the inside of the engine.
S Drain water from the sea water pump.
10.3.2 Taking the engine out of operation for 3 to 6 months

If the engine is shut down for more than 3 months, engine preservation is necessary in addition to the
measures mentioned in 10.3.1.
10.3.2.1 Fuel system preservation

The fuel system and the combustion chambers of the engine are preserved by operation with the
anti-corrosion fuel. Anti-corrosion fuel is a mixture of conventional diesel fuel and 2 vol. % anti-corrosion
agent, see MAN factory standard M3069.
The fuel system must be preserved as follows:
S Keep anti-corrosion fuel ready in a container.
S Connect the fuel system of the engine to this container.
S Operate the engine that has warmed up with anti-corrosion fuel for 3 minutes at nominal speed.
S Operate the engine for 2 minutes at idling speed.
S Switch off the engine.
S Close the openings for intake air and exhaust gas air-tight until the engine is still hot.
10.3.2.2 Preserving the intake and exhaust gas system

S Spray corrosion protection oil (see MAN factory standard M3249, Temporary corrosion protection MAN
part number 09.11002-0025) into the air intake manifold and exhaust pipe.
S Close the openings for intake air and exhaust gas air-tight until the engine is still hot.

10.4 Restarting engines that have been shut down

Proper and careful restarting of new engines or those that have already been run has a great impact on
their operational safety and residual service life. Basically, you must endeavor to preserve engines at the
time of shutting them down. When doing so, the regulations specified in the MAN works standard M3069
must be observed.
Tip for users

The engines are provided ex-factory with preservation according to the M3069 factory standard.
The factory standard is available from the customer service department at the Nuremberg factory.
If the engine had not been preserved before being shut down, there is the danger of cylinder liners, piston
rings and valves getting corroded, especially if the intake air and exhaust gas openings have not been
closed and the engine has been stored outdoors. Foreign substances that have penetrated, rainwater and
similar sometimes require complete disassembly of the engine.
This is why you need to differentiate in the procedure for start-up between engines that have been
preserved and those that have not been preserved:
10.4.1 Putting preserved engines into operation according to the M 3069 MAN
factory standard
1. Remove external preservation and do not use a high-pressure cleaner under any circumstances.
2. Remove the cap from the intake and exhaust gas outlet.
3. Check the cooling system, fill with antifreeze according to the service products list (see the "Service
products ..." publication for this purpose), check the concentration and correct it if required.
4. Check the engine oil level, and fill with fresh approved engine oil if required.
5. Add fuel, bleed the system.
Check the function of the monitoring and emergency shut-down equipment.
6. Check elastic connecting elements such as V-belt, coolant and charge air hoses for their condition, and
check for proper assembly or correct tensioning.
7. Crank the engine with the starter without filling it up until oil pressure builds up, and operate the stater
for maximum 5 seconds while doing so.
8. Allow filling and start the engine.
9. Check the engine for leakage points, check for abnormal noise development and observe the oil
pressure and temperature. Start up the engine by increasing the load in steps.
10.After maximum 25 hours of operation, drain preservation oil from the engine and replace the oil filter,
then refill with fresh approved engine oil.
Tip for users

For more information, see the MAN service product database.
You can find approved products on the Internet at:

10.4.2 Commissioning of unpreserved engines

In addition to the steps for a preserved engine, commissioning unpreserved engines requires the following
additional work, depending on potential damage caused during standstill.
1. Perform endoscopy on the combustion chambers and disassemble and install injectors for this purpose.
Check the valves for free movement, check the valve clearance and adjust it if required.
Replace damaged / corroded parts.
2. Drain used engine oil from the engine and replace the oil filter, then refill with fresh approved engine oil.
3. Check the cooling system for corrosion, check the coolant for its concentration and condition, and
replace it in case of doubt. First clean the coolant chambers and, if necessary, remove and install the
coolant pump and thermostats, replace the axial face seal of the coolant pump and the thermostat
inserts, and test the cooling system under pressure.
4. Check the clean air system, air filter and exhaust gas turbocharger for dirt or impurities, and clean or
repair them if required.
5. Clean the fuel system and drain the old fuel if necessary. Check the filter, and clean or replace it, if
necessary.
10.5 Decommissioning and recommissioning of the DEF/AdBlue®/AUS32 system

For information, see "Modular aftertreatment system" maintenance instructions.

Technical data
11 Technical data
11.1 Weight specifications

Ensure that suitable lifting gear is used for handling the engine and the engine parts listed in the table.
Designation Weight (kg)

Crankcase 500
Crankshaft 135
Flywheel 38 - 55
Additional flywheel mass 37
Flywheel housing 30
Elastic coupling 97
Intercooler 74
Exhaust gas turbocharger 32
Coolant expansion tank 45
Oil pan 40
Oil filter, selectable 27 or 88
Engine carriage 107
11.2 Dimensions and weight
Specification D2868 LE466 D2862 LE4XX Unit

Weight (dry) - 2270 kg
A - 2060 mm
B - 1157 mm
C - 1230 mm
11.3 Requirements for the installation site and space requirements

Observe the information in the installation instructions.

Technical data
11.4 Engine data - Light duty
11.4.1 D2868 LE466 (V8)
Emission level IMO Tier II / US Tier 3

Design V 90°
Principle of operation 4-stroke Diesel
Combustion process Direct injection
Turbocharging 2-stage exhaust turbocharging with intercooling and charge air
control (waste gate)
Number of cylinders 8
Cylinder bore 128 mm
Piston stroke 157 mm
Displacement 16 160 cm3
Compression ratio -- : 1
Operating mode Up to 500 operating hours per year, 5 % time proportion full load,
mean utilization max. 50 %
Power
D2868 LE466 956 kW / 1300 HP at 2300 rpm
Max. torque
D2868 LE466 4350 Nm at 1200 - 2100 rpm
Firing order 1-5-7-2-6-3-4-8
Valve clearance, with cold engine
Intake valve 0.50 mm
Exhaust valve 0.80 mm
Fuel system
High-pressure pump Bosch CP 3.4
Injection system Common rail
Controller Electronically controlled Diesel injection (EDC) - Type EDC 17
Injectors 8-hole nozzles
Engine lubrication Force-feed lubrication
Oil change quantity (with filter) 60 l
Oil filter 2 oil modules with 2 oil coolers each and one oil separator
Engine cooling Liquid cooling
Coolant temperature 80 - 90 °C, for a short time 95 °C is permissible
Electrical equipment
Starter 24 V; 7.0 KW
Three-phase alternator 28 V; 1x 120 A or 2x 120 A

Technical data
11.4.2 D2862 LE496
Emission level IMO Tier II / US Tier 3

Design V 90°
Compression ratio -- : 1
Operating mode Up to 500 operating hours per year, 5 % time proportion full load,
mean utilization max. 50 %
Power
D2862 LE496 1471 kW / 2000 HP at 2300 rpm
Max. torque
D2862 LE496 6500 Nm at 1200 - 2100 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Fuel system

Technical data
11.4.3 D2862 LE459
Emission level IMO Tier III

Design V 90°
Compression ratio 17 : 1
Operating mode Up to 1000 operating hours per year, 20 % time proportion full
load, mean utilization max. 50 %
Power
D2862 LE459 1213 kW / 1650 HP at 2300 rpm
Max. torque
D2862 LE459 5518 Nm at 1200 - 2300 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Fuel system

Technical data
11.5 Engine data - Medium duty
11.5.1 D2862 LE428 / LE 438 / LE469
Emissions levels IMO Tier III / US Tier 4

Design V 90°
Turbocharging Turbocharger with intercooling and charge air control (waste gate)
Power
D2862 LE428 749 kW / 1018 HP at 2100 rpm
D2862 LE438 882 kW / 1200 HP at 2100 rpm
D2862 LE469 974 kW / 1325 HP at 2100 rpm
Max. torque
D2862 LE428 3780 Nm at 1300 - 1900 rpm
D2862 LE438 4450 Nm at 1300 - 1900 rpm
D2862 LE469 4897 Nm at 1300 - 1900 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Fuel system

Technical data
11.5.2 D2862 LE489
Emissions levels IMO Tier III / US Tier 4

Design V 90°
Power
D2862 LE428 1066 kW / 1450 HP at 2100 rpm
Max. torque
D2862 LE428 5358 Nm at 1200 - 1900 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Fuel system

Technical data
11.6 Engine data - Heavy duty
11.6.1 D2862 LE427 / LE 437 / LE447
Emissions levels IMO Tier III / US Tier 4 (D2862 LE427 / LE447)

Emissions levels IMO Tier III (D2862 LE437)
Design V 90°
Turbocharging Turbocharger with intercooling and charge air control (waste gate)
Operating mode unlimited
Power
D2862 LE427 662 kW / 900 HP at 1800 rpm
D2862 LE437 551 kW / 750 HP at 1800 rpm
D2862 LE447 735kW / 1000 HP at 1800 rpm
Max. torque
D2862 LE427 3950 Nm at 1000 - 1600 rpm
D2862 LE437 3290 Nm at 1000 - 1600rpm
D2862 LE447 4380 Nm at 1000 - 1600 rpm
Firing order 1-12-2-11-3-10-6-7-5-8-4-9
Fuel system

Installation drawings
12 Installation drawing D2862 LE4XX
in creation
Identification number of the installation drawing: 51.00512-XXXX

102

103

104
Directories
13 Directories

Directories
13.1 Abbreviations
A . . . . . . . . . Ampere kW . . . . . . . Kilowatt
Ah . . . . . . . . Ampere hours m . . . . . . . . Meter
API . . . . . . . American Petroleum Institute MANcats . MANcomputer assisted testing
and diagnostic system
ASTM . . . . American Society for Testing
and Materials MAX . . . . . . Maximum
AUS . . . . . . Aqueous Urea Solution min. . . . . . . Minutes
AUS 32 . . . Aqueous Urea Solution per MIN . . . . . . Minimum
ISO 22241
mm . . . . . . . Millimeter
BDC . . . . . . Bottom dead center
Nm . . . . . . . Newton-meter
C . . . . . . . . . Celsius
NOx . . . . . . Nitrous Oxides
CAN . . . . . . Network for control devices and data
perm. . . . . . Permissible
bus systems in the vehicle (Controller
Area Network) poss. . . . . . Possible
C.F.R . . . . . Code of Federal Regulations OEM . . . . . Original Equipment Manufacturer
cm3 . . . . . . Cubic centimeter rpm . . . . . . . Revolutions per minute
EDC . . . . . . Electronically controlled diesel SAE . . . . . . Society of Automotive Engineers
injection (Electronic Diesel Control) SCR . . . . . . Selective Catalytic Reduction
e.g. . . . . . . . For example T . . . . . . . . . Terminal
EPA . . . . . . Environmental Protection Agency TDC . . . . . . Top dead center
ETC . . . . . . Exhaust gas turbocharger UBat ....... Battery voltage
etc. . . . . . . . Etcetera (and so on) ULSD . . . . . Ultra Low Sulfur Diesel
ggf. . . . . . . . If required or applicable V . . . . . . . . . Volt
h . . . . . . . . . Hour W . . . . . . . . Watt
ISO . . . . . . . International Organization for > . . . . . . . . . Greater than
Standardization
< . . . . . . . . . Less than
kg . . . . . . . . Kilogram
. . . . . . . . . See

Directories
13.2 Keyword Index
A F
Aftertreatment system maintenance Faults, 90
instructions, 89 Fill with fuel, 73
Alarms, initiating, 90 Filling with coolant, 74
Alternator, Attachment, 44 Flywheel, 32
Flywheel housing, 32
B Fuel pre-filter, Drain the water, 83
Bleeding the fuel system, 73 Fuel system, Description, 31
Bolted connections, 43
I
C Information about these instructions, 7
Classification, General, 32 Information on the engine type label, 28
Conduct in the event of a hazard, 23 Injection system, 31
Connecting the fuel lines, 54 Installation - Engine, 42
Connecting the oil filter, 47 Installation and commissioning, 41
Content of these instructions, 14 Intake and exhaust system, 32
Control and operation, 75
Coolant level, Checking, 78 L
Cooling system, 31 Limitation on liability, 10
Cooling system , 51
M
Copyright protection, 10
Maintenance and care, 89
Customer service, 12
Maintenance Manual, 89
D Maintenance schedule, 89
Decommissioning and recommissioning, 91 Maintenance work, 89
Design and operation, 31 Modifications and conversions, 14
Dimensions and weight, 95
O
Disposal, 11
Operating ranges, 88
E Other applicable documents, 10
Electrical system, Connecting the starter motor, 63
P
Emission label, EPA, 29
Packaging, 37
Engine data, 96
Personal protective equipment, 16
Engine description, 31
Plugs on engine, 66
Engine foundation, 46
Preface, 7
Engine lubrication, 31
Preparations prior to operation, 76
Engine monitoring, 31
Proper use, 13
Engine oil, Checking the engine oil level, 81
Protective device , 65
Engine type label, 27
Protective devices, 22
Engine views, 33
Environmental protection, 25
Exhaust system, Exhaust gas outlet at engine, 59
Explanation of icons, 9
Externally mounted cooling system, Connections
on the engine, 52

Directories
R
Repair manual, 89
Requirements for the installation site and space
requirements, 95
Requirements of personnel, 15
Responsibility of the operating company, 14
Restarting engines that have been shut down, 93
S
Safety equipment, 22
Service support locations, 90
Signage, 24
Spare parts, 11
Special hazards, 17
Start-up, Preparations, 72
Starter, 63
Starting the engine, 87
Storage, 37
Switching off the engine, 87
T
Taking out of operation temporarily, 92
Technical data, 95
Transport, 38
Transport inspection, 37
Transport, packaging and storing, 35
W
Warranty provisions, 12
Weights, 95


Operating Instruction: MAN Marine Diesel Engines D2868 LE4XX / D2862 LE4XX

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Operating Instruction: MAN Marine Diesel Engines D2868 LE4XX / D2862 LE4XX

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Operating Instruction

MAN Marine Diesel Engines

MAN Marine Diesel Engines

D2868 LE4XX / D2862 LE4XX

51.99587-5056 "Original instruction"

Subject to change without prior notice.

MAN Truck & Bus SE

Technical status as on: 09/2019

Read these instructions carefully before starting any work!

2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Engine type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Design and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5 Transport, packaging and storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Read these instructions carefully before starting any work!

6 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7 Control and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10 Decommissioning and recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Read these instructions carefully before starting any work!

12 Installation drawing D2862 LE4XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Read these instructions carefully before starting any work!

Read these instructions carefully before starting any work!

Engine types Output in kW Nominal speed Emission level Aftertreatment system

1.1 Information about these instructions

Read these instructions carefully before starting any work!

1.1.1 Supplementary publications to these instructions

1.1.2 Other publications

Read these instructions carefully before starting any work!

1.2 Explanation of icons

Tips and Recommendations

Tip for users

Read these instructions carefully before starting any work!

1.3 Limitation on liability

1.4 Copyright protection

Tip for users

1.5 Other applicable documents

Read these instructions carefully before starting any work!

1.6 Spare parts

Tip for users

Order spare parts from an authorized dealer or directly from MAN.

Read these instructions carefully before starting any work!

1.8 Warranty provisions

1.9 Customer service

Tip for users

Read these instructions carefully before starting any work!

2 General safety instructions

2.1 Proper use

Read these instructions carefully before starting any work!

2.2 Content of these instructions

2.3 Modifications and conversions to the engine

2.4 Responsibility of the operating company

Read these instructions carefully before starting any work!

2.5 Requirements of personnel

Tip for users

2.5.2 Unauthorized persons

Read these instructions carefully before starting any work!

2.6 Personal protective equipment

Industrial protective clothing

Clothing for special work

Read these instructions carefully before starting any work!

2.7 Special hazards

For this reason:

For this reason: