Man D 0824 LE 201 User manual

3
Operating Instructions –
MAN Industrial Diesel Engines

4

Preface
5
Dear Customer,
these Operating Instructions are intended to familiarize you with your new MAN Diesel
engine and how it operates.
This manual is supplemented by the publication “Fuels, Lubricants and Coolants for MAN
Diesel Engines” and the “Service record”.
Note:
All three publications belong to the engine and must always be kept ready to hand
near the engine in the engine room.
Please read this Manual and the “Instructions for the installation of MAN Diesel Engines”
before you put the new engine into operation.
Comply in full with instructions relating to operation, prevention of accidents and envi-
ronmental protection.
MAN Diesel engines are developed and manufactured in line with the latest state of the
art. However, trouble-free operation and high performance can only be achieved if the
specified maintenance intervals are observed and only approved fuels, lubricants and
coolants are used.
It is imperative and in your own interest to entrust your MAN Local Service Centre with
the removal of any disturbances and with the performance of checking, setting, and re-
pair work.
Yours faithfully
MAN Nutzfahrzeuge Aktiengesellschaft
Nuremberg works
We reserve the right to make technical modifications in the course of further development.
2001 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation, even of extracts, is not allowed without written permis-
sion from MAN. All rights under the copyright law are strictly reserved by MAN.
MTDA Technical status: 06.2001 51.99493–8342

Contents
6
Page
Declaration 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplates 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety regulations 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning and operation
Engine views D 0824 LE 201 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First commissioning 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation monitoring system 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting down 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and care
Lubrication system 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary fuel supply pump 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intercooler 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary decommissioning of engines 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting table 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For data see original declaration
If required this declaration is enclo-
sed with the delivery note.
Declaration
7
Declaracion
In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of
Directive 89/392/EEC, version 93/44/EEC
MAN Nutzfahrzeuge Aktiengesellschaft,
hereby declares that the engine described below is destined for installation in a machine
as defined in the EC directive on machines.
Engine model:
Design:
Engine number:
Rating / speed:
Note:
The manufacturer of the complete ready-to-use machine in which this engine is to be
installed must take the further action necessary in the context of indirect safety-re-
lated engineering and provision of instructions to ensure that the ready-to-use ma-
chine complies with the requirements of the EC directive on machines.
The engine must not be put into operation until the complete machine satisfies the
conditions laid down in the EC directive on machines 89/392/EEC, most recently
amended by 93/44/EEC, or the latest amendment of said directive.
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33
D–90441 Nürnberg

Nameplates
8
In all your correspondence please always quote engine model, serial number and job
number (Order number).
For this reason it is advisable to read off the data from the engine type plates before put-
ting the engine into operation and to enter them in the appropriate spaces.
The engine type plates are on the crankcase.
Model ......................................................................
delivered on ......................................................................
installed on ......................................................................
Engine serial number ......................................................................
Order number ......................................................................
MAN Nutzfahrzeuge Aktiengesellschaft
Typ
Motor-Nr. / Engine No. NI/II
Temp. C
Werk Nürnberg Germany
:
MAN Nutzfahrzeuge AktiengesellscMAN Nutzfahrzeuge Aktiengesellschaft
:
:
Altitude mRating BHP
Job No Rating kW Speed rpm
Serial NoModelYear
–0219
Aufstellhohe m uNNLeistg. PS
Drehz. 1/min
Leistung kWWerk–Nr.
Motor–Nr.TypBauj.
°

Safety regulations
9
General notes
Day-to-day use of power engines and the service products (fuels, lubricants, cool-
ants) necessary for running them presents no problems if the persons occupied
with their operation, maintenance and care are given suitable training and think as
they work.
This summary is a compilation of the most important regulations. These are broken down
into main sections which contain the information necessary for preventing injury to per-
sons, damage to property and pollution. In addition to these regulations those dictated by
the type of engine and its site are to be observed also.
Important:
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the
eyes etc., consult a doctor immediately.
1. Regulations designed to prevent accidents with injury to persons
During commissioning, starting and operation
DBefore putting the engine into operation for the first time, read the oper-
ating instructions carefully and familiarize yourself with the “critical”
points. If you are unsure, ask your MAN representative.
DFor reasons of safety we recommend you attach a notice to the door of
the engine room prohibiting the access of unauthorized persons and that
you draw the attention of the operating personal to the fact that they are
responsible for the safety of persons who enter the engine room.
DThe engine must be started and operated only by authorized personnel.
Ensure that the engine cannot be started by unauthorized persons.
DWhen the engine is running, do not get too close to the rotating parts.
Wear close-fitting clothing.
DDo not touch the engine with bare hands when it is warm from operation
– risk of burns.
ËË
DExhaust gases are toxic. Comply with the instructions for the installation
of MAN Diesel engines which are to be operated in enclosed spaces.
Ensure that there is adequate ventilation and air extraction.

Safety regulations
10
DKeep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
During maintenance and care
DAlways carry out maintenance work when the engine is switched off.
If the engine has to be maintained while it is running, e.g. changing the
elements of change-over filters, remember that there is a risk of scald-
ing. Do not get too close to rotating parts.
DChange the oil when the engines is warm from operation.
Caution:
There is a risk of burns and scalding. Do not touch oil drain plugs or oil
filters with bare hands.
ËË
ËË
DTake into account the amount of oil in the sump. Use a vessel of suffi-
cient size to ensure that the oil will not overflow.
DOpen the coolant circuit only when the engine has cooled down.
If opening while the engine is still warm is unavoidable, comply with the
instructions in the chapter entitled “Maintenance and Care”.
DNeither tighten up nor open pipes and hoses (lube oil circuit, coolant cir-
cuit and any additional hydraulic oil circuit) during the operation.
The fluids which flow out can cause injury.
DFuel is inflammable. Do not smoke or use naked lights in its vicinity. The
tank must be filled only when the engine is switched off.
DWhen using compressed air, e.g. for cleaning the radiator, wear goggles.
DKeep service products (anti-freeze) only in containers which can not be
confused with drinks containers.
DComply with the manufacturer’s instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.

Safety regulations
11
2. Regulations designed to prevent damage to engine and premature wear
Do not demand more from the engine than it is able to supply in its intended application.
Detailed information on this can be found in the sales literature. The injection pump must
not be adjusted without prior written permission of MAN Nürnberg.
If faults occur, find the cause immediately and have it eliminated in order to prevent more
serious damage.
Use only genuine MAN spare parts. MAN will accept no responsibility for damage result-
ing from the installation of other parts which are supposedly “just as good”.
In addition to the above, note the following points:
DNever let the engine run when dry, i.e. without lube oil or coolant.
DWhen starting do not use any additional starting aids (e.g. injection with starting pilot).
DUse only MAN-approved service products (fuel, engine oil, anti-freeze and anti-cor-
rosion agent). Pay attention to cleanliness. The Diesel fuel must be free of water. See
“Maintenance and care”.
DHave the engine maintained at the specified intervals.
DDo not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
DNever put cold coolant into an overheated engine. See “Maintenance and care”.
DDo not add so much engine oil that the oil level rises above the max. marking on
the dipstick. Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered to.
DAlways ensure that the testing and monitoring equipment (for battery charge, oil pres-
sure, coolant temperature) function satisfactorily.
DComply with instructions for operation of the alternator. See “Maintenance and care”.

Safety regulations
12
3. Regulations designed to prevent pollution
Engine oil and filter elements / cartridges, fuel / fuel filter
DTake old oil only to an old oil collection point.
DTake strict precautions to ensure that no oil or Diesel fuel gets into the drains or the
ground.
The drinking water supply could be contaminated.
DFilter elements are classed as dangerous waste and must be treated as such.
Coolant
DTreat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.
DWhen disposing of spent coolant comply with the regulations of the relevant local auth-
orities.

Safety regulations
13
4. Notes on safety in handling used engine oil ∗
Prolonged or repeated contact between the skin and any kind of engine oil decreases the
skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal experi-
ments. If the basic rules of hygiene and health and safety at work are observed, health
risks are not to the expected as a result of handling used engine oil.
Health precautions:
DAvoid prolonged or repeated skin contact with used engine oil.
DProtect your skin by means of suitable agents (creams etc.) or wear protective gloves.
DClean skin which has been in contact with engine oil.
– Wash thoroughly with soap and water. A nailbrush is an effective aid.
– Certain products make it easier to clean your hands.
– Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
DAfter washing apply a fatty skin cream to the skin.
DChange oil-soaked clothing and shoes.
DDo not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly
– Engine oil can endanger the water supply –
For this reason do not let engine oil get into the ground, waterways, the drains or the
sewers. Violations are punishable.
Collect and dispose of used engine oil carefully. For information on collection points
please contact the seller, the supplier or the local authorities.
∗Adapted from “Notes on handling used engine oil”.

Commissioning and operation
14
Engine views D 0824 LE 201
1
2
3
4
5
6
7
8
12
11
10
9

Commissioning and operation
15
1 Oil filler neck
2 Thermostat housing
3 Injection pump
4 Starter motor
5 Oil filter head with oil cooler
6 Oil filter
7 Water pump
8 Fan
9 GAC-Governor
10 Tensioning pulley
11 Turbocharger
12 Crankcase breather

Commissioning and operation
16
First commissioning
At the time of initial commissioning of a new or overhauled engine make sure to have ob-
served the “Technical Information for the installation of MAN Diesel engines”.
It is recommended that new or overhauled engines should not be operated at a load
higher than about 75% maximum load during the first few hours of operation. Initial run-in
should be at varying speeds. After this initial run-in, the engine should be brought up to
full output gradually.
Note:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Other-
wise the manufacturer’s warranty will become null and void.
Filling with fuel
Caution:
Fill the tank only when the engine is switched off. Pay attention to cleanliness.
Do not spill fuel.
Use only approved fuels, see brochure “Fuels, lubricants etc.”.
Filling-in of coolant
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze
agent on the ethylene glycole basis or anti-corrision agent.
See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.
DPour in coolant slowly via expansion tank, see page 27
Filling with engine oil
Caution:
Do not add so much engine oil that the oil level rises above the max. marking on the
dipstick. Overfilling will result in damage to the engine.
The engines are as a rule supplied without oil.
Pour oil into engine via filler neck, see page 21.
For the quantity required see “Technical Data”.

Commissioning and operation
17
Commissioning
Before daily starting the engine, check fuel level, coolant level and engine oil level and
replenish, if necessary.
Note:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Other-
wise the manufacturer’s warranty will become null and void.
Checking oil level
Check the oil level when the engine is horizontal, but only if at least 20 minutes have
passed since the machine was switched off.
DPull out dipstick (arrow)
Dwipe it with a clean, lintfree cloth
Dand push it in again up to the stop
DPull out dipstick again
The oil level should be between the two
notches in the dipstick and must never fall
below the lower notch. Top up oil as
necessary.
Caution:
Do not add so much engine oil that the
oil level rises above the max. marking
on the dipstick. Overfilling will result in
damage to the engine.
Ensure outmost cleanliness when hand-
ling fuels, lubricants and coolants.
Oil
?
MIN
MAX

Commissioning and operation
18
Starting
Danger:
Before starting make sure that no-one is in the engine’s danger area.
Caution:
When starting do not use any additional starting aids (e.g. injection with starting pilot).
DEnsure that no load is on the engine before starting it, eg switch off load, disengage
clutch, put gearbox into neutral etc.
DInsert starter key in starting lock
DPress starter button until engine starts
Caution:
DWhen engine starts, release starter button immediately
Dlf engine does not start, actuate starter for about 10 seconds, wait for 30 seconds
and then attempt to start engine again and so on
With engine with automatic starting it is indispensable that none of the moving parts be
accessible. Warning signs “Unit starts automatically” are to be attache to the engine. Re-
gulation on this which may apply locally are to be satisfied.
When engine is running, lube oil pressure must build up at the oil pressure gauge. If not
switch off engine immediately.
Avoid running the cold engine for any length of time since in any internal combustion en-
gine this is liable to cause increased wear due to corrosion. Prolonged idling is harmful to
the environment.

Commissioning and operation
19
Operation monitoring system
Caution:
Do not overload the engine. Do not exceed the maximum permissible tilt of the
engine. If faults occur, find their cause immediately and have them eliminated in order
to prevent more serious damage!
During operation the oil pressure in the engine lubrication system must be monitored.
If the monitoring devices register a drop in the lube oil pressure, switch off the engine im-
mediately.
Shutting down
Do not switch off engine immediately operation at high loads, but let it idle for about
5 minutes to achieve a temperature equalisation.
Then switch off the engine via the shut-off device provided (electric speed governor).
Danger:
Ensure that the engine cannot be started by unauthorized persons

Maintenance and care
20
Lubrication system
Ensure outmost cleanliness when handling fuels, lubricants and coolants.
Note:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Other-
wise the manufacturer’s warranty will become null and void.
Engine oil change
Danger:
The oil is hot- risk of scalding.
Do not touch the oil drain plug
with bare fingers. Oil is an envi-
ronmental hazard. Handle it
with care!
While the engine is warm from operation
remove the oil drain plug from the oil pan
and let all old oil drain out.
Use a vessel of sufficient size to ensure
that the oil does not overflow.
Refit the oil drain plug with a new seal.
Note:
Change the oil filter element every
time the engine oil is changed.