Use only genuine MAN spare parts and accessories or those approved by MAN. Only MAN approved genuine spare parts have been tested by us and thus suitable for use in our engines. A particular concern of MAN is to improve environmental protection. This begins with the development and design of our engines.
MAN-Industrial diesel engines D2842 LE103 Foreword 1.2 Key to Symbols Warnings Warnings are identified in these Operating Instructions with symbols. These warnings are pre ceded by signal words that express the magnitude of the risk. Always heed these warnings and act prudently to prevent accidents, injuries and property damage.
MAN and the law applicable at the time of contracting arrangements. 1.4 Copyright Please handle these Operating Instructions as confidential. They are only to be used by the persons work ing with the engine. Transfer to a third party without explicit written permission from MAN is strictly prohib ited. NOTE! The information, texts, drawings, illustrations and other depictions are all protected by copy...
1.6 Spare Parts Use only genuine MAN spare parts and accessories or those approved by MAN. Only MAN approved genuine spare parts have been tested by us and are thus suitable for use in our en gines. Spare parts and accessories must either be original MAN parts or parts that are expressly approved by MAN.
Valid are the commitments agreed upon in the delivery contract and the General Terms and Conditions of MAN and the law applicable at the time of contracting arrangements. Non-adherence to this operating instruction and, if included, supplier operating instructions, renders claims under the warranty null and void.
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MAN-Industrial diesel engines D2842 LE103 Foreword Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
The engine is built exclusively for the driving of self-propelled machines. 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.
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.
MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 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...
MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 2.6 Personal Protective Equipment Wearing personal protective equipment is necessary to minimise the health risks when working. S The required personal protective equipment for the relevant job must always be worn while working.
MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 2.7 Specific Dangers The following section describes residual risks which have been identified. S Observe the safety instructions listed here and the warnings in the other chapters of these instructions in order to reduce health hazards and avoid dangerous situations.
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MAN-Industrial diesel engines D2842 LE103 General Safety Instructions Highly Flammable Substances - Diesel Fuel, Oils and Grease WARNING! Risk of fire caused by highly flammable substances! Highly flammable substances, fluids or gases can catch on fire and cause serious or deadly injuries.
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MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 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 cloth...
MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 2.8 Safety Equipment The operator must have the following safety equipment in place: Before the engine is placed into operation, install the emergency-off equipment and connect it into the safety chain of the system.
MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 2.9 Conduct in Dangerous Situations and When Accidents Occur Preventative Measures S Always be prepared for an accident! S Keep first aid equipment (first aid kit, blankets, etc.) and fire extinguishers at hand.
MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 2.10 Signs The following symbols should be installed in the immediate vicinity of the hazard area. WARNING! Risk of injury caused by illegible symbols! In the course of time, stickers and symbols become dirty or unrecognisable for other reas...
MAN-Industrial diesel engines D2842 LE103 General Safety Instructions 2.11 Environmental Protection CAUTION! Environmental hazard caused by incorrect handling! Incorrect handling of environmentally hazardous substances, especially when incorrectly disposed of, can cause considerable damage to the environment. For this reason: S Always heed the information below.
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MAN-Industrial diesel engines D2842 LE103 General Safety Instructions Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Engine Model Plate Engine Model Plate For all communications please always give the en gine model (3), engine number (4) and work num ber/job number (5). Therefore, before the initial start up of the engine, read and note/enter if appropriate the correspond...
MAN-Industrial diesel engines D2842 LE103 Engine Model Plate 3.1 Explanation of the Motor-Nr./Engine-No. (Engine Identification Number) Motor-Nr./Engine-No. Class identifier (assignment) Model number according to index of model codes 1234 Day of assembly (plant internal) Assembly order (sequence number on day of assembly) 3.2 Explanation of Model Designation...
MAN-Industrial diesel engines D2842 LE103 Design and Function Design and Function 4.1 Engine, General The 12 cylinder engines described here are liquid-cooled 4-stroke cycle diesel engines with turbocharging and intercooling. Engine Monitoring Monitoring of the engine is made through various sensors. The sensors are designed, for example, as rpm and temperature sensors, which report the various operating conditions of the engine to the engine control unit.
MAN-Industrial diesel engines D2842 LE103 Design and Function 4.2 Engine Views 4.2.1 Front Right View (1) Combustion air line to the charge-air cooler (2) Combustion air line from the charge-air cooler (3) coolantconnection (4) 3-phase generator (5) Coolant pump (6) Oil cooler...
MAN-Industrial diesel engines D2842 LE103 Design and Function 4.2.2 Front Left View (1) Turbocharger (2) Oil separator valve for crankcase ventilation (3) Oil dipstick (4) Exhaust pipe (5) Oil filler neck (6) Starter (7) Oil pan (8) Oil drain plug...
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MAN-Industrial diesel engines D2842 LE103 Design and Function Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Transport, Packaging and Storage Transport, Packaging and Storage It is absolutely necessary to observe the “Assembly Instructions” for the installation and commissioning of a new or reconditioned engine. NOTE! Installation and commissioning is only to be made by the employees of the manufacturer of the entire system or by manufacturer's authorised personnel.
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MAN-Industrial diesel engines D2842 LE103 Transport, Packaging and Storage 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 hooked up properly, these packages could tip over and fall causing serious injuries.
MAN-Industrial diesel engines D2842 LE103 Transport, Packaging and Storage 5.3 Transport Inspection Check the delivery for missing items and for damage from transport. If external signs of transport damage are apparent: S Do not accept delivery or only accept under written protest.
MAN-Industrial diesel engines D2842 LE103 Transport, Packaging and Storage 5.4 Transport Lifting Points There are 2 lifting lugs (1) and (2) for the crane installed on the engine. WARNING! Risk of death caused by the load falling! During lifting operations, loads can fall down. This can cause serious injury and even death.
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MAN-Industrial diesel engines D2842 LE103 Transport, Packaging and Storage 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.
MAN-Industrial diesel engines D2842 LE103 Transport, Packaging and Storage 5.5 Packaging Packaging The individual packages are packed in accordance with the expected conditions of transport. The purpose of the packaging is to protect the components from transport damage, corrosion and other damage.
S Safety Shoes S Safety Gloves 6.2 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 and commissioning! Installation and commissioning require trained qualified personnel with sufficient experi...
6.3.2 Engine Model Plate Data Please always specify the engine model, engine number and order number when corresponding with MAN, see page. Therefore, before the commissioning of the engine read off the appropriate data from the engine type plates and enter these in the section relating to the engine type plates, see page 25.
MAN-Industrial diesel engines D2842 LE103 Installation and Commissioning 6.4 Commissioning Operate new and overhauled engines at no greater than around 3/4 load during the initial hours of opera tion; however operate at varying engine speeds. After this time period the engine can be slowly brought up to full power.
MAN-Industrial diesel engines D2842 LE103 Installation and Commissioning 6.4.2 Filling Coolant NOTE! Do not let coolant drip or leak out while filling. Do not let coolant leak out onto the ground or into water sources. Otherwise, the environment will be damaged.
MAN-Industrial diesel engines D2842 LE103 Operation Operation 7.1 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.
MAN-Industrial diesel engines D2842 LE103 Operation 7.3 Preparations before Operation DANGER! Danger caused by damaged engines! Damaged engines can be dangerous to persons. For this reason: S Check engine for damage and leaks before each operation. S Do not operate engine if damage is found.
The cooling system is under pressure and the coolant is hot. For this reason: S Let engine cool down first NOTE! The cooling system is not included in MAN's scope of delivery. Check the coolant level according to the manufacturer's operating manual. 7.3.3 Refilling Coolant NOTE! Do not let coolant drip or leak out while refilling.
MAN-Industrial diesel engines D2842 LE103 Operation 7.3.4 Checking Engine Oil Level NOTE! Check the oil level when the engine is horizontal and only after at least 20 minutes have passed since the engine was switched off. 1. Pull out oil dipstick (1).
MAN-Industrial diesel engines D2842 LE103 Operation 7.3.5 Refilling Engine Oil IMPORTANT! Termination of liability for material defects by use of non-approved fluids and lubric ants! 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 ..."...
MAN-Industrial diesel engines D2842 LE103 Operation 7.4 Operation 7.4.1 Monitoring Operation IMPORTANT! Do not overload engine. If faults occur, investigate and solve them immediately to prevent major damage from oc curring! The engine oil pressure is monitored during its operation.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Maintenance and Care 8.1 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.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care IMPORTANT! Termination of liability for material defects by use of non-approved fluids and lubric ants! Liability for material defects is terminated if non-approved fluids and lubricants are used. For this reason: S Only use approved fluids and lubricants (see “Fluids and Lubricants ..." publication).
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MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Maintenance Schedule Maintenance Intervals Maintenance Work Check coolant level and oil level Check air filter for dirt Retighten the cylinder head bolts, 1st retightening. (on overhauled engine) Check tension of V-belts and tighten if necessary or replace if worn...
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4 Maintenance Work 8.4.1 Engine Oil Change WARNING! Risk of scalding! Engine oil is hot. For this reason: S Only touch the oil drain screws using protective gloves NOTE! The oil filter elements are to be replaced at every engine oil change.
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MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Replace oil filter insert 1. Drain oil from oil filter bowl as described previ ously. 2. Remove filter bowl (4) after loosening the fixing screw (3). 3. Replace filter insert (5). Thoroughly clean all remaining parts in cleaning fluid.
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MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Filling Engine Oil IMPORTANT! Termination of liability for material defects by use of non-approved fluids and lubric ants! Liability for material defects is terminated if non-approved fluids and lubricants are used. For this reason: S Only use approved fluids and lubricants (see “Fluids and Lubricants ..."...
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MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Check Engine Oil Level NOTE! Check the oil level when the engine is horizontal and only after at least 20 minutes have passed since the engine was switched off. 1. Pull out oil dipstick (1).
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4.2 Cleaning Fuel Prefilter DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled. For this reason: S Work carefully. S Do not spill any fuel.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4.3 Fuel Filter - Drain Condensation DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled. For this reason: S Work carefully. S Do not spill any fuel.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4.4 Changing Fuel Filter Element DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled. For this reason: S Work carefully. S Do not spill any fuel.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4.5 Bleeding the Fuel System DANGER! Fire hazard caused by uncontrolled fuel leakage When opening the fuel system, fuel can leak out uncontrolled. For this reason: S Work carefully. S Do not spill any fuel.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4.6 Changing Coolant Drain coolant WARNING! Risk of scalding! The cooling system is under pressure and the coolant is hot. For this reason: S Let engine cool down first NOTE! Do not let coolant spill while draining. Do not let coolant leak out onto the ground or into wa...
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MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Add/vent coolant (only on a cold engine) WARNING! Risk of scalding! If, in an exceptional case, the cooling circuit needs to be opened with the engine hot from operation, hot coolant may spray out.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4.7 Air filter IMPORTANT! Engine damage due to contaminated combustion air! The entry of unfiltered air can lead to greatly increased cylinder and piston wear. For this reason: S Always operate the engine with the air filter fitted.
MAN-Industrial diesel engines D2842 LE103 Maintenance and Care 8.4.8 V-belt replacement Check the condition of the V-Belt When wear or a different tension is detected on one V-Belt of a multi-V-Belt drive, the complete set of V-Belts must always be replaced.
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MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Tension and replacement of V-Belt 1. Loosen fixing bolts (1). 2. Loosen lock nut (2). 3. Reset adjuster nut (3), until the V-Belts have the correct tension. 4. Retighten the lock nut and fixing bolts.
The water/ air charge cooler is a part supplied by MAN and requires no regular cleaning. Air / Air charge air cooling systems are not supplied by MAN. These charge air cooling systems are to be cleaned after discussion with the vehicle manufacturer and depending on the level of soiling.
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MAN-Industrial diesel engines D2842 LE103 Maintenance and Care Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Faults Faults The following chapter describes the possible faults that can occur and the work required to correct them. For those faults that cannot be rectified by the following information, contact the manufacturer of the entire system or MAN.
MAN-Industrial diesel engines D2842 LE103 Faults 9.3 Fault Table The column “Remedial measures” is only completed, if from the "probable cause" what needs to be done is not appar Fault Possible cause Remedy D Fuel tank empty Engine does not start...
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MAN-Industrial diesel engines D2842 LE103 Faults Fault Possible cause Remedy D inadequate fuel in the tank Engine speed fluctua D Air in fuel system tions during operation D Tachometer faulty D Injectors faulty D Too much power is demanded from the...
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MAN-Industrial diesel engines D2842 LE103 Faults Fault Possible cause Remedy D Engine cold Lube-oil pressure too D Selected oil viscosity is inappropriate for D See "Fluids and Lubricants..." high ambient temperature (too thick) D Oil pressure indicator faulty D Safety valve in oil circuit faulty (does not...
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MAN-Industrial diesel engines D2842 LE103 Faults Fault Possible cause Remedy D Engine not at correct operating tempe D Let engine warm to operating Engine knocking rature temperature before running at full load D Check thermostat D Valve clearance not OK...
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MAN-Industrial diesel engines D2842 LE103 Faults Starter Fault Possible cause Remedy (This column is only filled in when it is not clear from the "probable cause" what needs to be done) To be repaired by a vehicle elec trician or by the manufacturer...
MAN-Industrial diesel engines D2842 LE103 Shutdown and restart Decommissioning and Recommissioning 10.1 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.
Shutdown and restart 10.3 Temporary Decommissioning of Engines Temporary anticorrosion protection according to MAN works norm M 3069 is required for engines which are to be put out of service depending on the duration. The works norm can be obtained from our After-Sales Service department Nuremberg works.
MAN-Industrial diesel engines D2842 LE103 Shutdown and restart 10.4 Recommissioning of Decommissioned Engines 10.4.1 Commissioning of Preserved Engines according to MAN-Werknorm (works standard) M 3059 1. Remove external preservation. Never use a high pressure cleaner for this. 2. Remove caps from intake and exhaust openings.
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MAN-Industrial diesel engines D2842 LE103 Shutdown and restart Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Technical Data Technical Data 11.1 Dimensions and Weights Specification Value Unit Weight (dry) D2842 LE103 1553 1161 11.2 Installation Location and Space Requirements Observe the information in the Installation Instructions. Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Technical Data 11.3 Engine Data 11.3.1 D2842 LE 103 Engine model D2842 LE 103 Design V 90° Operating Principle 4-Stroke diesel with supercharging and charge air cooling Combustion system Direct injection Charging Exhaust turbocharger with charge air cooling...
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MAN-Industrial diesel engines D2842 LE103 Technical Data Engine lubrication Force feed lubrication Oil capacity in oil sump (litres) min. max. 24 l 32 l 35 l Oil change quantity (with filter) Lubrication oil pressure during operation (depending on engine speed, oil temperature and engine...
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MAN-Industrial diesel engines D2842 LE103 Technical Data Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Declaration of incorporation Declaration of incorporation For data see original declaration Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
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MAN-Industrial diesel engines D2842 LE103 Declaration of incorporation Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
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MAN-Industrial diesel engines D2842 LE103 Declaration of incorporation Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
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MAN-Industrial diesel engines D2842 LE103 Declaration of incorporation Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Index of terms and contents 13 Index of terms and contents Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Index of terms and contents 13.2 Technical Terms EDC, Electronic Diesel Control is an electronically controlled diesel injection system. This positively affects the fuel consumption, economy, exhaust and noise behaviour. Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
MAN-Industrial diesel engines D2842 LE103 Notes Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Carefully read the Operating Instructions before starting any work! This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
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MAN Truck & Bus AG Vogelweiherstraße 33 90441 Nürnberg Germany A member of the MAN Group Printed in Germany 51.99493-8579...
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