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

Assembly Instruction
MAN Industrial Diesel Engines

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

D2862 LE221 / LE223 / LE231 / LE233
51.99496-5024 “Original instruction”

Version 01
Information and Copyright
Subject to change.
The information, text, drawings, pictures and other illustrations that it contains are protected by copyright
and are subject to industrial property rights. Anx misuse is punishable by law.
It is not permitted to change the contents of this document. The same applies to changes to the context of
individual chapters and/or the whole document. MAN Truck & Bus assumes no liability for any damages
arising from non-compliance with the above provisions.
Reprinting, copying or translation, even of extracts, is not allowed without written permission from MAN. All
rights under the copyright law are strictly reserved by MAN.
© 2019
MAN Truck & Bus SE
Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
Email: [email protected]
Internet: www.engines.man.eu
Technical status: 02.2018

51.99496-5024
Carefully read the Assembly Instructions before starting any work!

This is especially valid for the chapter on General Safety Instructions
2 and the safety instructions in each of the chapters.
Content
Information and Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Applicability of the assembly instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Important additional information regarding the assembly instruction . . . . . . . . . . . . . 5
1.1.2 Supplementary information with reference to the assembly instruction . . . . . . . . . . . 5
1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Restriction of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Applicable documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

4.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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

7.1 Version with cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2 Version with Duralite air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Foreword
1 Introduction
1.1 Applicability of the assembly instruction

This assembly instruction provides important information for the setup of stationary MAN Industrial Diesel
Engines in the Series D2862 LE221/223/231/233 from the Nürnberg production facility following their
delivery Ex-Works.
NOTE!
Planning of the installation must already have taken place in the project phase. The basis
for this is the installation instruction for MAN Industrial Diesel Engines for the driving of
alternators and pumps (51.99493-8443). The assembly instruction first comes into force,
when the planning is completed and the engine is ready for installation in the plant (Power
set).
All questions relating to the installation of the engine should be clarified during the planning of the diesel
engine plant. The scope of delivery should also be established in this project phase. After delivery of the
engine, in accordance with the contract, installation in the plant can commence.
Compliance with all safety precautions and handling instructions are prerequisites for safe working con
ditions. Furthermore, the valid local accident prevention regulations for the engine's area of application and
the general safety regulations must be followed.
1.1.1 Important additional information regarding the assembly instruction

- Installation drawing
- Shipping documents for engine
1.1.2 Supplementary information with reference to the assembly instruction

- Operating instruction (included in the scope of delivery)
- Maintenance instruction (included in the scope of delivery)
- Fuels, Lubricants and Coolants for MAN Industrial Diesel Engines (included in the scope of delivery)
For service personnel

- Repair instructions
- Spare parts catalogue (included in delivery)

Foreword
1.2 Explanation of symbols
Warnings
Warnings are identified in these Operating Instructions with symbols. These warnings are prece
ded by signal words that express the magnitude of the risk.
Always heed these warnings and act prudently to prevent accidents, injuries and property damage.
DANGER!
... indicates an imminently hazardous situation, which leads to death or serious injuries if
not avoided.
WARNING!
... indicates a possible hazardous situation, which can lead to death or serious injuries if not
avoided.
CAUTION!
... indicates a possible hazardous situation, which can lead to minor or light injuries if not
avoided.
IMPORTANT!
... indicates a possible hazardous situation, which can lead to minor or light injuries if not
avoided.
Tips and Recommendations

NOTE!
highlights useful tips and recommendations as well as information for efficient and smooth
operation.
General Information
• This symbol indicates a list at the first level.
- This symbol indicates a list at the second level.
1. This symbol indicates a sequence of actions.
(1) In the text, this symbol indicates a position in a graphic.

Foreword
1.3 Restriction of liability

All information and statements in this instruction have been compiled with due consideration of the relevant
standards and regulations, the state-of-the-art and also our many years of experience and knowledge.
MAN is not liable for damages resulting from:
S Failure to follow these instructions
S Improper use
S Use of untrained personnel
S Customer conversions
S Technical modifications
S Use of non-approved spare parts and fluids and lubricants
The actual scope of delivery for special versions, additional ordering options or technical modifications may
deviate from what is described and illustrated in these instructions.
The stipulations agreed in the delivery contract and the general terms of sale and supply of MAN are appli
cable, as well as the statutory regulations in force at the point in time of the conclusion of the contract.
1.4 Copyright protection

Please handle these Operating Instructions as confidential. They are only to be used by the persons wor
king with the engine. Transfer to a third party without explicit written permission from MAN is strictly prohibi
ted.
NOTE!
The information, texts, drawings, illustrations and other depictions are all protected by copy
right and are subject to industrial property rights. Any improper use is punishable by law.
1.5 Applicable documentation

Supplier components are built into the engine (e.g. cooling system). For these bought-out parts the risk
assessments have been carried out by the respective supplier.
Compliance of the design with the applicable European and national regulations has been declared by the
respective suppliers of the components.

Foreword
1.6 Spare parts

Use only genuine MAN spare parts and accessories or those approved by MAN.
Only MAN approved genuine spare parts have been tested by us and are thus suitable for use in our en
gines.
Spare parts and accessories must either be MAN genuine parts or parts that have been specifically appro
ved by MAN. The reliability, safety and suitability of these parts have been established specifically for the
engines. We cannot assess and vouch for other non-MAN products, despite ongoing market observations.
WARNING!
Risk of injury from incorrect spare parts!
Incorrect or faulty spare parts can lead to damage, incorrect function or complete failure
and may affect safety.
For this reason:
S Only use MAN genuine parts
NOTE!
Please always specify the engine model, engine number and order number when corre
sponding with MAN, see page .25
1.7 Disposal
Dispose in accordance with national regulations.
If no return or disposal agreement has been made, recycle the disassembled components as follows:
S Sort metals before scrapping
S Recycle plastic parts
S Dispose of all other parts according to their material composition

Foreword
1.8 Warranty conditions

The stipulations agreed in the delivery contract and the general terms of sale and supply of MAN are appli
cable, as well as the statutory regulations in force at the point in time of the conclusion of the contract.
Failure to observe these assembly Instructions and any accompanying supplier assembly instructions leads
to the loss of warranty claims.
The use of non-approved parts leads to the loss of warranty claims.
We recommend the use of original parts, even after the expiry of the warranty period, in order to ensure the
continuing performance of the engine.
1.9 Customer service

Our MAN product support is available for technical information.
NOTE!
Please always specify the engine model, engine number and order number when corre
sponding with MAN, see page .25
Information about contact persons can always be called up by telephone, email or via the Internet. For
addresses see page 2.

Foreword

General Safety Instructions
2 General Safety Instructions

This chapter provides information on the risks and dangers during the intended use of the engine.
Universally applicable safety instructions that should be followed are listed, which provide for the optimum
protection of personnel and the safe and faultless operation of the engine.
In the following, specific, action and situation-related safety information is placed before the corresponding
step, or in the chapter described.
Failure to observe the handling information and safety instructions provided in this installation instruction
can result in considerable danger.
2.1 Intended use

The engine is built exclusively for emergency power operation (LTP) and peak load operation (PRP).
Any other use is considered as "not intended".
MAN is not liable for any damage resulting from use that is not intended. The risk is entirely borne by the
operator.
Intended use also includes compliance with the prescribed operating, maintenance and repair work.
The engine may only be used, maintained and repaired by persons who are familiar with the engine and
have been informed of the hazards.
Unauthorised modifications to the engine shall void any liability for any resulting property damage and per
sonal injury.
Likewise, the manipulation of the injection and control system could affect the performance and emission
characteristics of the engine. Compliance with the statutory environmental requirements can therefore no
longer be guaranteed.
DANGER!
Danger from not using the product as intended!
Any use that exceeds the intended use and/or any different use of the engine can lead to
dangerous situations which will invalidate the operating permit.
For this reason:
S Only use the engine for its intended purpose.
S The engine is only for use outside hazardous (Ex) zones.

2.2 Content of the assembly instruction

Any person who is instructed to perform assembly work, must have read and understood these Assembly
Instructions before starting any work. This also applies if the person has worked with such an engine or a
similar engine, or has already been trained by MAN.
Reading and understanding the Assembly Instructions is thus mandatory.
2.3 Modifications and changes to the engine

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

The operator of the motor is subject to the statutory requirements for workplace safety.
In addition to the Safety at Work Instructions in these Assembly Instructions, the safety regulations, acci
dent prevention regulations and environmental protection regulations valid for the application area of this
engine must also be observed.
In particular:
S The operator must be knowledgeable about the valid occupational health and safety regulations and be
able to assess, in a risk analysis, the dangers that are present in the specific working conditions at the
operating site of the engine. He must then implement these safety regulations in the form of operating
instructions for the operation of the engine.
S During the entire period of operation of the engine the operator must check whether the operating in
structions he created meet the most current standards for regulations and revise them if necessary.
S The operator must clearly define and regulate the responsibilities for installation, operation, maintenance
and cleaning of the product.
S The operator must ensure, that all employees who are concerned with the engine have read and un
derstand the operating instruction.
In addition, he must instruct the personnel at regular intervals and inform them of the dangers.
S The operator must provide the personnel with the necessary protective equipment.
S These assembly instructions must be kept in the immediate vicinity of the engine and be readily accessi
ble at any time to those persons working on and with the engine.
The operator is responsible for ensuring that the engine is always operated in perfect working condition and
working order.
In particular:
S Maintenance work, such as that described in the Operating Instructions or Maintenance Instructions is
to be completed within the prescribed time intervals or carried out by a MAN service workshop/MAN
contract partner.
S The operator must have all safety equipment checked regularly for function and integrity.
S The instructions in the Operating Instructions are to be followed completely and fully!

2.5 Personnel requirements
2.5.1 Qualifications
WARNING!
Risk of injury caused by insufficient qualifications!
Improper handling can result in significant personal injury and property damage
For this reason:
S Specific activities must only be performed by those persons who are named in the re
spective chapters in these Operating Instructions.
The following qualifications will be designated in the Operating Instructions for various task areas.
S Instructed Persons
Have been instructed in a briefing about the possible dangers of improper handling in their tasks.
S Qualified Personnel
Due to their technical training, knowledge and experience and knowledge of the relevant regulations
they can properly perform the tasks assigned to them.
S Electrical Specialist
Is capable of performing work on electrical systems due to his/her technical education/training, know
ledge and experience as well as knowledge of the respective standards and regulations and can recog
nise and avoid any possible dangers.
The electrical specialist is trained for the specific operating site in which he/she works and knows the
relevant standards and regulations.
S When selecting personnel, observe the regulations regarding age and profession valid at the operating
site.
2.5.2 Unauthorised persons
WARNING!
Danger for unauthorised persons!
Unauthorised persons, who do not satisfy the requirements stated here, do not realise the
dangers in the work area.
For this reason:
S Keep unauthorised persons out of the working area.
S In case of doubt, address the person and remove him/her from the working area if ne
cessary.
S Interrupt the work until all unauthorised persons are out of the working area.
2.5.3 Instruction
Personnel must be regularly instructed. For better traceability, the execution of this instruction must be re
corded.

2.6 Personal protection equipment

Wearing personal protective equipment is necessary to minimise the health risks when working.
S The required personal protective equipment for the relevant job must always be worn while working.
S All signs pertaining to personal protective equipment in the working area must be followed.
Protective Clothing
Close-fitting clothing with low initial tear strength, with narrow sleeves and with no pro
truding parts. It is used primarily to protect against injury, weather and dirt.
No rings, bracelets, necklaces and other jewellery are to be worn while working.
Protective Helmet
To protect the head from falling or flying objects.
Safety Shoes
To protect the feet from heavy falling objects and from slipping on slick surfaces.
Safety Gloves
To protect the hands from friction, scraping, punctures or deep injuries and to protect
from hot or caustic parts or fluids
To be worn when performing specific types of work

When performing certain types of work, special protective equipment is required. These will be specifically
mentioned in the relevant chapters.
Safety Glasses
To protect the eyes from flying objects and spraying fluids.
Hearing Protection
To protect the ears from damage by loud noises.

2.7 Special dangers

In the following section risks are named, which have been determined.
S Observe the safety instructions listed here and the warnings in the other chapters of these instructions
in order to reduce health hazards and avoid dangerous situations.
Electrical Current
DANGER!
Risk of death caused by electrical current!
There is a risk of death when coming into contact with parts conducting electrical currents.
Damaged insulation or components can be life threatening.
For this reason:
S In the event of damage to the insulation, immediately shut down the engine and make
arrangements for repair work to be undertaken.
S Any work performed on the electrical system may only be made by a qualified electrician.
S When working on the electrical system the power supply must be switched off and then
properly checked to ensure no electrical current is present.
S Before starting any maintenance, cleaning or repair work the power supply must be swit
ched off and secured from being accidentally switched back on.
S Do not jumper across fuses or render them inoperable. When changing fuses, make sure
that the replacement is of the correct amperage.
S Keep moisture clear of parts conducting electrical current. This could cause a short-cir
cuit.
Moving Parts
WARNING!
Risk of injury caused by moving parts!
Rotating or linear moving parts can cause serious injuries.
For this reason:
S During operation do not reach into or tamper with moving parts.
S Do not open the covers during operation.
S Observe the run-on time: before opening any covers ensure that no parts are still moving.
S Wear close-fitting clothing in the hazard area.
Multi-engine plants
WARNING!
Risk of injury due to engines in the vicinity!
In the event of damage to an engine, persons in the operating area may be in danger.
For this reason:
S Restrict the period of stay of persons in the operating area to that which is absolutely ne
cessary.
S Fit separating protective devices to running engines..
S Waiting in the operating area is only permitted with the running engines at low load con
ditions.

Exhaust gases
WARNING!
Danger to health from exhaust gases!
Lack of sealing in the exhaust system can lead to harmful exhaust gases in the machine
room.
For this reason:
S Make sure that there is adequate ventilation.
S Immediately shutdown machines with leaking exhaust systems.
Highly flammable substances - Oils and grease
WARNING!
Risk of fire caused by highly flammable substances!
Highly flammable materials (lubricating oils, greases) can catch fire and cause serious inju
ries and death.
For this reason:
S Do not smoke in the hazard area or in the vicinity.
No open fires or sources of ignition.
S Keep fire extinguishers at hand.
S Immediately report any suspicious substances, fluids or gases to the person in charge.
S In the case of fire, immediately stop working. Leave hazard area until the danger is over.
Coolants - Antifreeze, Anticorrosion Agents
WARNING!
Risk of injury caused by coolants that are hazardous to health
Coolants contain substances that are hazardous to your health. Contact with these sub
stances can lead to serious poisoning, allergies, skin irritations and damage to eyes.
For this reason:
S Follow the manufacturer's safety sheets.
S Always wear protective clothing, chemical-resistant protective gloves and safety glasses.
S Avoid spilling or spraying these substances.
Hot Fluids and Lubricants
WARNING!
Risk of burns caused by hot fluids and lubricants!
Fluids and lubricants can reach high temperature while in operation and cause burns when
coming into contact with them.
For this reason:
S Before handling any fluids and lubricants, check whether they are hot. If necessary, let
them cool down first.

Hot Surfaces
CAUTION!
Risk of burns caused by hot surfaces!
Contact with hot components can cause burns.
For this reason:
S When performing any work in the vicinity of hot components always wear protective clo
thing and protective gloves.
S Before starting any work ensure that all components have cooled down to ambient tempe
rature.
Noise
WARNING!
Risk of hearing damage caused by noise!
The level of noise occurring in the working area can cause serious damage to hearing.
For this reason:
S Always wear hearing protection when working.
S Do not unnecessarily remain in the hazard area. Leave hazard area when work is finis
hed.
Sharp Edges and Corners
CAUTION!
Risk of injury caused by sharp edges and corners!
Sharp edges and pointed corners can cause cuts and abrasions on the skin.
For this reason:
S Always work carefully and with caution in the vicinity of sharp edges and corners.
S In cases of doubt, wear protective gloves.
Dirt and Objects
CAUTION!
Risk of tripping caused by dirt and objects!
Dirt and discarded objects become the cause of tripping and falling and can be the cause of
considerable injury.
For this reason:
S Always keep the work area clean.
S Remove any objects that are no longer necessary.
S Mark areas where there is a danger of tripping with yellow and black striped tape.

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

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

2.8 Safety devices
Before the engine is commissioned the operator must fit the following safety devices:
WARNING!
Risk of death caused by non-operational safety equipment!
Safety equipment ensures maximum safety during operation. Even if they may make wor
king more complicated, they must not be overridden. Safety can only be guaranteed if the
safety equipment is intact and operational.
For this reason:
S Before starting any work, check whether all of the safety equipment is correctly installed
and in good operating order.
S Before starting the engine, check whether all of the safety equipment is correctly installed
and in good operating order.
2.8.1 Emergency-Stop device

The Emergency-Stop device must be connected in such a way, that if the power supply is interrupted or
restored following an interruption, dangerous situations for persons and material assets are excluded.
The emergency-off equipment must always be freely accessible.
2.8.2 Belt guards

The belt drives of the alternator and the fan must be provided with covers, so that dangerous situations for
persons and material assets can be excluded.
2.8.3 Fan cover

The fan is to be fitted with a cover to exclude dangerous situations for persons and material assets.
2.8.4 Heat protection covers for exhaust pipes and turbine housings
Exhaust pipes and turbine housings must always be protected by means of suitable covers in order to ex
clude dangerous situations for persons and material assets.

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

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

2.10 Signs and notices

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

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


Identification of the Engine
3 Engine type plate
The engines may only be used in accordance with

their use laid down in the planning stage, also see
chapter “General Safety Instructions”, section 2.1.
Therefore, it is important for the plant manufac
turer technician to be able to reliably identify each
engine.
A clear identification is only possible using the in
formation on the engine type plate.
The engine type plates (1) and (2) are mounted on
the crankcase.
MAN Nutzfahrzeuge Aktiengesellschaft

Aktiengesellsc
Werk Nürnberg Germany
:
Bauj. Year Typ Model Motor−Nr. Serial No
Werk−Nr. Job No Leistung kW Rating kW Drehz. 1/min Speed rpm
Temp.°C Leistg. PS Rating BHP Aufstellhohe m uNN Altitude m

:
:
−0219

Identification of the Engine
3.1 Explanation of Engine No./Engine No. (Engine identification number)

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

Model designation Declaration Example
D Fuel type Diesel
28 Figure + 100 128 mm bore
6 Stroke figure (rounded) 157 mm stroke
2 Number of cylinders 12 cylinders
L Charging With supercharger and
intercooling
E Installation engine Built-in engine for
current generation plants
221/223/231/233 Model designation identification 2= Equipment set engine
2 = Common Rail
1/3 = Serial number

Transport, Packaging and Storage
4 Transport, packaging and storage

It is absolutely necessary to observe the “Installation Instructions” for the installation and commissioning of
a new or reconditioned engine.
NOTE!
Installation and commissioning is only to be made by the employees of the manufacturer of
the entire system or by manufacturer authorised personnel.
4.1 Prerequisite
Before starting any work read and observe the General Safety Instructions and the safety information in this
chapter.
Strictly observe these instructions and act prudently to avoid accidents, personal injury and property damage.
Personal Protective Equipment

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

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

4.3 Transport inspection

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

4.4 Transport
Lifting Points
3 crane hook eyelets (1) are provided for lifting the engine.
WARNING!
Danger of death due to falling load!
During lifting operations loads may fall. This may result in serious injury or even death.
For this reason:
S Use the „Crane eyelets“ only for the transport of the engine, without additional supporting
components.

Transport with Crane

The engine can be transported with a crane under the following conditions.
S The crane and the lifting equipment must be designed for the weight of the engine.
S Make sure ropes and chains do not pull crookedly on the crane hooks.
S The operator must be qualified for operating the crane.
1. Attach the ropes, straps or multipoint lifting equipment according to the picture.
2. Ensure that the package is hanging straight or compensate for the off-centre point of gravity.
3. Start the transport.
Transport with Forklift

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

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

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

Installation
5 Installation
5.1 Prerequisite
Before starting any work read and observe the General Safety Instructions and the safety information in this
chapter.
Strictly observe these instructions and act prudently to avoid accidents, personal injury and property damage.
Personal Protective Equipment

The following protective equipment must be worn:
S Protective Clothing
S Safety Shoes
S Safety Gloves
5.2 Safety instructions
Personnel
S The installation and commissioning may only be performed by MAN employees or by MAN-trained quali
fied personnel.
WARNING!
Danger caused by faulty installation!
Installation requires trained qualified personnel with sufficient experience. Faulty installation
can cause life threatening situations and considerable property damage.
For this reason:
S Installation and commissioning are only to be performed by trained and qualified per
sonnel.
Ground Rules
WARNING!
Risk of injury caused by improper installation!
Improper installation can case serious injuries or considerable property damage.
For this reason:
S Ensure adequate work space before starting any work.
S Be careful when working with exposed parts with sharp edges.
S Make sure work space is kept clean and orderly!
S Install components in a correct manner.
S Observe the prescribed tightening torques.
S Secure components so that they do not fall or tip over.
S It is absolutely necessary to observe the “Installation Instructions” for the commissioning of a new or
reconditioned engine.

Installation
5.3 Interfaces between engine and plant

Installation
The engine is a component of the complete plant (Power set). During the installation of the engine the fol
lowing assembly work is to be carried out on the interfaces between the engine and the plant:
(1) Connect charge air inlet, see page 41

(2) Connect starter (electrical plant), see page 43
(3) Connect the plug connector of the wiring harness, see page 44
(4) Connect charge air outlet, see page 41
(5) Connect coolant entry for the cooling system, see page 39
(6) Connect compensating reservoir for engine coolant, see page 39
(7) Connect exhaust system, see page 42
(8) Connect coolant outlet for the cooling system, see page 39
(9) Bolt the engine feet to the equipment set frame, see page 38
(10) Connect exhaust system, see page 42
(11) Install alternator, see page 36
(12) Connect fuel system, see page 41
5.3.1 Installation drawing
IMPORTANT!
The basis for the installation of the engine in the complete plant (Power set) is the in
stallation drawing. This provides information about the type of connections and their
dimensions.
For this reason:
S Please observe the installation drawing for each of the following assembly operations lis
ted.
5.3.2 Bolted connections

Always use a torque wrench to tighten the threaded connections.
The tightening torques of all of the standard threaded connections can be found listed on page 47.
IMPORTANT!
Damage to components caused by incorrectly tightened threaded connections
For this reason:
S If an impact wrench is used for the initial tightening, then the bolts may only be
tightened with a max. of 50% of the specified tightening torque.
S The final tightening stage may only be performed manually using a torque wrench.

Installation
5.4 Completion of the engine and assembly of the equipment set
5.4.1 Flange mounting of the alternator
IMPORTANT!
Many versions of alternators are available on the market (single-bearing or two-bearing)
and elastic couplings.
For this reason:
S Follow the installation instruction of the respective manufacturer!
Flywheel
The connection dimensions of the flywheel (1) are
stated on the installation drawing.
Remove oil, grease and preservative from the fly
wheel.
Flywheel housing
The connection dimensions of the flywheel housing
(2) are stated on the installation drawing.
NOTE!
The flywheel housing has connection dimensions in accordance with SAE0.

Installation
5.4.2 Check crankshaft axial clearance
IMPORTANT!
The designed crankshaft axial play of the engines must not in any event be reduced by the
installation of couplings or other components.
For this reason:
S It is essential to record the axial play of the crankshaft before and after any components
are installed by using a dial indicator held by a magnetic stand.
Measure the axial play of the crankshaft before and after installing the generator or other components onto
the engine.
S Remove crankshaft cover

S Place holder (1) and dial indicator (2) onto en
gine so that the probe of the dial indicator is
under tension on the vibration damper
S Press crankshaft all the way in the axial direc
tion to the flywheel housing
S Set dial indicator to zero
S Pull crankshaft all the way in the axial direction
from the flywheel housing
S Read off dial indicator
If the results of both measurements do not match
or if the crankshaft springs back after being pu
shed, check the installation.
Engines Crankshaft axial play

D2862 LE2.. 0.20-0.40 mm

Installation
5.5 Installation on the equipment set frame
NOTE!
Before placing the engine in the plant with the aid of the installation drawing, check whether
the interface dimensions of the lines (coolant, exhaust, etc.) to the connections at the en
gine fit.
WARNING!
For safety reasons, protective devices are incorporated on the engine, which pre
vent contact with hot and rotating components (protection from contact with the ex
haust manifold (hot!) and on the front of the engine (rotating crankshaft!)
For this reason:
S This protective equipment must not be removed!
5.5.1 Bolting the engine to the base frame
The installation drawing provides information on

the arrangement and also a hole drilling pattern for
the engine mountings (1) and the engine carriers
(3).
The mounting of the alternator is to be carried out
by the plant manufacturer.
1. Set the engine and alternator on the base
frame (if required, with elastic bearings).
2. Bolt the engine mounting (1), the engine carri
ers (3) and the alternator mounting to the base
frame. The bolt diameter (2) is stated on the
installation drawing.

Installation
5.6 Connect cooling system
5.6.1 Connect coolant lines for the engine cooling
The installation drawing specifies the implementa

tion of the coolant connections.
1. Connect coolant inlet (1)
2. Connect coolant outlet (2)
5.6.2 Connect expansion tank for engine coolant
1. Connect expansion tank for engine coolant to

hose connection (1).

Installation
5.6.3 Install cooling system
5.6.4 Connection parts 51.06100-6224 for fan cooler
Item No. Part No. Quantity Part name Tightening torque

1 06.03216-8507 2 6-hex.hd. Bolt M12x35
2 50.06240-0001 2 Cooler strut
3 06.67223-6095 4 Hose clamp 12 Nm
4 50.96305-0001 2 Moulded hose for coolant
5 51.97445-0086 6 Profile clamp 12 Nm
6 06.56938-4040 2 O-ring 150x3 N-FPM 1-80
7 50.09411-0004 2 Charge-air manifold
8 51.96320-0010 2 Corrugated hose DMR 140
9 06.67420-1218 2 Spring band hose clamp
10 04.27405-9510 1 Hose 10-5

Installation
5.7 Connect fuel lines

the fuel connections.
1. Connect fuel inlet (2)
2. Connect fuel return (1)
5.8 Connect air lines for the combustion air (Intercooling)
The installation drawing specifies the arrangement

of the combustion air connections.
1. Connect combustion air inlet (1)
2. Connect combustion air outlet (2)

Installation
5.9 Install exhaust system
5.9.1 Install exhaust pipe

the connection dimensions of the exhaust system.
1. Connect exhaust system to exhaust turbo
charger with weld flange (1).
1. Connect exhaust system to exhaust turbo

charger with exhaust elbow (1).
5.9.2 Install Exhaust gas compensators
IMPORTANT!
No loads from the exhaust system must not be transmitted to the turbocharger
For this reason:
S Install compensator at the exhaust outlet between the exhaust turbocharger and exhaust
system!
S Observe the installation instructions of the manufacturer!

Installation
5.10 Connect electrical system
5.10.1 Connect starter
Connection dimensions, clamp 30 (1)

Connection thread: . . . . . . . . . . M12x1.75
Tightening torque . . . . . . . . . . . . 20-30 Nm
Connection dimension clamp 31 (2)
Connection thread: . . . . . . . . . . M12x1.75
Tightening torque . . . . . . . . . . . . 20-30 Nm
Battery capacity, cable length and cable cross-sec
tion should be selected to match.
Engine models D2862 LE2..

Starter type Mitsubishi Electric Corporation
Rated voltage V 24
Rated output kW 7.0

Installation
5.10.3 Connect wiring harness plug connector
1. Connect wiring harness connector to adapter

(1) of the wiring harness
5.10.4 connect MFR control unit
The MFR has three connector housings, on one no

pins are fed through (3). On the connector housing
(1) the pins are prominent, however not internally
connected in the MFR. On delivery of the MFR this
connector housing is to be closed off with a cover
cap.
Only connector housing (2) is used, this is where
the wiring harness connector is plugged in.
IMPORTANT!
Danger of irreparable damage to the engine control unit!
S When installing the connector first fully open the locking device, then insert and lock the
plug connector.
IMPORTANT!
Danger of irreparable damage to the plug connectors!
S Protect disconnected plug connectors and contacts from the ingress of dirt.

Installation
5.11 Safety devices
WARNING!
Risk of death caused by the absence of safety equipment!
An emergency-off button, for shutting down the system or engine in an emergency, must be
installed for each engine.
For this reason:
S Install an emergency stop button to shut down the system in an emergency.
S Check whether all of the safety equipment is correctly installed and in good operating
order.
WARNING!
Danger of death due to incorrect operation!
In the event of overload or fault conditions the engine may overheat and stall suddenly as a
result.
For this reason:
S The sensors used to monitor the engine parameters must be connected to a monitoring
device of the module manufacturer and evaluated.
S When the sensor values are outside the permissible limits or in the event of a fall in
power, the engine must be immediately shut down via the monitoring device.

Installation
5.11.1 Install belt guard
WARNING!
On every engine the belt drives of the alternator and the fan must be fitted with guards.
For this reason:
S Install belt protection on both drives.
order.
1.. Install belt protection on both V-belt drives (1)

and (2).
5.11.2 Install fan cover
WARNING!
On each engine the fan must be fitted with a cover.
For this reason:
S Install fan cover
order.
1.. Fit fan (1) with a cover.

Installation
Tightening torques according to plant standard M 3059

Bolt/nut with Allen or hexagon head with no collar or flange
Thread size Strength classifications / tightening torque in Nm

x pitch
at 8.8 / 8 at 10.9 / 10 at 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

Installation

Commissioning
6 Commissioning
WARNING!
Danger caused by faults during commissioning!
Commissioning requires trained qualified personnel with sufficient experience. Improper
commissioning can cause life threatening situations and considerable property damage.
For this reason:
Commissioning is only to be performed by trained and qualified personnel.
Ground Rules
WARNING!
Risk of injury caused by improper commissioning!
Improper commissioning can case serious injuries or considerable property damage.
For this reason:
S Before commissioning the engine, carefully read the Operating Instructions and familia
rise yourself with the “critical” subjects.
S It is absolutely necessary to observe the “Installation Instructions” for the commissioning
of a new or reconditioned engine.
S Make sure work space is kept clean and orderly!
6.1 Fill with Fuels, Lubricants and Coolants
IMPORTANT!
Termination of liability for material defects through the use of non-approved fluids
and lubricants!
Liability of material defects is terminated if non-approved fluids and lubricants are used.
For this reason:
S Only use approved fluids and lubricants (see “Fluids and Lubricants ..." publication).

Commissioning
6.1.1 Fill with engine oil
IMPORTANT!
Engine oil is harmful to the environment.
For this reason:
S Do not let engine oil spill while filling. Do not let engine oil leak out onto the ground or into
bodies of water.
The engines are as a rule supplied without oil.

Fill engine with lubricating oil via the oil filler
opening (1),
Oil quantity with filter Litres

D 2862 LE2.. 93
IMPORTANT!
Engine damage will occur if engine oil level is too low or too high!
For this reason:
S Do not fill engine oil above the max. mark on the dipstick

Commissioning
6.1.2 Check engine oil level
Check engine oil level 30 minutes after filling en

gine with oil.
1. Remove oil dipstick (1).
2. Wipe oil dipstick with fibre-free, clean cloth.
3. Reinsert the oil dipstick up to the stop.
4. Withdraw the oil dipstick and check the oil level.
The oil level should be between the two notches
on the dipstick and must not fall below the lower
notch.
5. Reinsert the oil dipstick (1) up to the stop.
If the oil level is too low, the oil tank must be
topped up with fresh engine oil.
MAX.
MIN

Commissioning
6.1.3 Filling with coolant

Fill the cooling system of the engine with a mixture of tap water and ethylene glycol antifreeze agent or an
ticorrosion agent.
IMPORTANT!
Coolant is harmful to the environment.
For this reason:
S Do not let coolant spill when filling. Do not let coolant leak out onto the ground or into bo
dies of water.
Further information on the preparation of the coolant is contained in the publication “Fuels, Lubricants and
Coolants for MAN Industrial and Ships Diesel Engines”. The quantity of coolant to be prepared is given by
the total filling quantity of the cooling system ( see Operating Instruction).
Special tools
[1] Connecting piece M26x1,5 51.981310279

SS Filling with coolant
Coolant may only be filled at the filler neck.

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

Commissioning
6.2 Commissioning the cooling system

When inspecting the coolant circuit make sure that
S The coolant circuit can be quickly filled (w 8 l/min);
S The coolant circuit is completely vented;
S No vacuum can be produced ahead of coolant pump (cavitation);
S A system pressure is achieved in the cooling circuit (0.4-0.5 bar static) and is maintained after engine is
turned off;
S The required coolant flow rate is achieved in the coolant circuit at max. permissible coolant temperature
and with mixture valve completely opened;
S No coolant leaks out of coolant circuit even when engine is turned off at a high temperature;
S Approx. 10% of the coolant quantity can be drained from the expansion reservoir until air is swept along
in the filling line;
S The coolant circuit including engine and heat exchanger can be completely drained;
S Air bubbles are released from the coolant;
S No air pockets are present in cooling system;
S Hose connections are accessible for maintenance.

Commissioning

Installation drawing for the engines D2862 LE221/223
7 Installation drawing for the engines D2862 LE221/223
7.1 Version with cooling system
Identification No. of installation drawing: 51.00512-7142,

drawn May 15, 2014, Index h
55
Identification no. of installation drawing: 51.00512-7142,

drawnMay 15, 2014, Index h
56

57

58

59

60
7.2 Version without cooling system, with Duralite air filter

61

62

63

64

65

66
8 Installation drawing for the engines D2862 LE231/233
8.1 Version with cooling system
Identification no. of installation drawing: 51.00512-7167

67

68

69

70

71

72
8.2 Version without cooling system

73

74

75

76

77

78
MAN Truck & Bus SE
Vogelweiherstraße 33
90441 Nuremberg
Germany
[email protected]
www.man-engines.com

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Assembly Instruction

MAN Industrial Diesel Engines

MAN Industrial Diesel Engines

51.99496-5024 “Original instruction”

Technical status: 02.2018

Carefully read the Assembly Instructions before starting any work!

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

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

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

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

Carefully read the Assembly Instructions before starting any work!

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

Carefully read the Assembly Instructions before starting any work!

1.1 Applicability of the assembly instruction

1.1.1 Important additional information regarding the assembly instruction

1.1.2 Supplementary information with reference to the assembly instruction

For service personnel

Carefully read the Assembly Instructions before starting any work!

1.2 Explanation of symbols

Tips and Recommendations

Carefully read the Assembly Instructions before starting any work!

1.3 Restriction of liability

1.4 Copyright protection

1.5 Applicable documentation

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1.6 Spare parts

Carefully read the Assembly Instructions before starting any work!

1.8 Warranty conditions

1.9 Customer service

Carefully read the Assembly Instructions before starting any work!

Carefully read the Assembly Instructions before starting any work!

2 General Safety Instructions

2.1 Intended use

Carefully read the Assembly Instructions before starting any work!

2.2 Content of the assembly instruction

2.3 Modifications and changes to the engine

2.4 Responsibility of the operator

Carefully read the Assembly Instructions before starting any work!

2.5 Personnel requirements

2.5.2 Unauthorised persons

Carefully read the Assembly Instructions before starting any work!

2.6 Personal protection equipment

To be worn when performing specific types of work

Carefully read the Assembly Instructions before starting any work!

2.7 Special dangers

Carefully read the Assembly Instructions before starting any work!

Highly flammable substances - Oils and grease

Coolants - Antifreeze, Anticorrosion Agents

Hot Fluids and Lubricants

Carefully read the Assembly Instructions before starting any work!

Sharp Edges and Corners

Dirt and Objects

Carefully read the Assembly Instructions before starting any work!

Working on the Common Rail System

Carefully read the Assembly Instructions before starting any work!

Carefully read the Assembly Instructions before starting any work!

2.8 Safety devices

2.8.1 Emergency-Stop device

2.8.2 Belt guards

The installation drawing specifies the implementa