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Related Manuals for Man D 0824 LE 201
Summary of Contents for Man D 0824 LE 201
- Page 3 Operating Instructions – MAN Industrial Diesel Engines...
- Page 5 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.
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Page 6: Table Of Contents
Commissioning and operation Engine views D 0824 LE 201 .......... -
Page 7: Declaration
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. -
Page 8: Nameplates
The engine type plates are on the crankcase. Model ..............delivered on ..............installed on ..............Engine serial number ..............Order number ..............MAN Nutzfahrzeuge Aktiengesellschaft Motor-Nr. / Engine No. NI/II MAN Nutzfahrzeuge Aktiengesellsc MAN Nutzfahrzeuge Aktiengesellschaft Werk Nürnberg Germany Bauj. Year Model Motor–Nr. Serial No Werk–Nr. -
Page 9: Safety Regulations
D Do not touch the engine with bare hands when it is warm from operation – risk of burns. Ë Ë D Exhaust 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. - Page 10 Safety regulations D Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences. During maintenance and care D Always 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.
- Page 11 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”.
- Page 12 Safety regulations 3. Regulations designed to prevent pollution Engine oil and filter elements / cartridges, fuel / fuel filter D Take old oil only to an old oil collection point. D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
- Page 13 Safety regulations 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.
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Page 14: Commissioning And Operation
Commissioning and operation Engine views D 0824 LE 201... - Page 15 Commissioning and operation 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...
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Page 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. -
Page 17: Commissioning
Commissioning and operation 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. -
Page 18: Starting
Commissioning and operation 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). D Ensure that no load is on the engine before starting it, eg switch off load, disengage clutch, put gearbox into neutral etc. -
Page 19: Operation Monitoring System
Commissioning and operation 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. -
Page 20: Maintenance And Care
Maintenance and care 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. - Page 21 Maintenance and care Refilling with 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. Fill up with fresh engine oil via oil filler neck (arrow) on cylinder head cover.
- Page 22 Maintenance and care Changing oil filter Remove filter cartridge using tape wrench. Use a vessel of sufficient size to ensure that the oil does not overflow. Danger: The filter cartridge is filled with hot oil - risk of burning and scal- ding! Lightly oil the seal (arrow) of the new filter.
- Page 23 Maintenance and care Changing oil filter Continuous operation A changeover-type oil filter, the filter el- (both filter halves ements of which can be replaced even in operation) during operation, can be fitted on request. However, oil filter cartridges must be Right-hand filter changed at every oil change.
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Page 24: Fuel System
Maintenance and care Fuel system Fuel If Diesel fuel which contains moisture is used the injection system and the cylinder liners / pistons will be damaged. This can be prevented to same extent by filling the tank as soon as the engine is switched off while the fuel tank is still warm (formation of conden- sation is prevented). - Page 25 Maintenance and care Fuel filter Draining moisture: Unsrew drain plugs at every oil change until moisture has been discharged and clean fuel flows out Changing fuel filter Only when the engine is swiched off. D Loosen filter cartridge by means of tape wrench, unscrew it by hand and take it D Moisten the seals on the new filter car- tridge with fuel...
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Page 26: Cooling System
Maintenance and care Cooling system Danger: Draining hot coolant involves a risk of scalding. Draining the cooling system Caution: Drain coolant into a suitable container and dispose of it in accordance with regulations. Drain coolant as follows when cooling sys- tem has cooled down D To let off pressure briefly open cap (large cap) on filler neck of expansion... - Page 27 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”. Coolant must be added at the filler neck only (large cap).
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Page 28: Intercooler
Maintenance and care Intercooler If the coolant output is to be retained as far as possible, the intercooler must be cleane- dat certain intervals. Air filter An air filter is installed in the vehicle to purify the air for combustion. The intervals at which the air cleaner requires servicing depend on the specific operating conditions encountered. -
Page 29: V-Belts
Maintenance and care V-belts Checking condition D Check V-belts for cracks, oil, overheat- ing and wear D Change demaged V-belts If, in the case of a multiple belt drive, wear or differing tensions are found, always re- place the complete set of belts. Checking tension Use V-belt tension tester to check V-belt tension. - Page 30 Maintenance and care Tensioning and changing V-belt water pump – tension pulley D Remove fixing bolts À D Remove lock-nut Á D Adjust nut  until V-belts have correct tensions D Retighten lock-nut and fixing bolts To change the V-belts turn the adjusting back and swing the tension pulley in- wards.
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Page 31: Turbocharger
Connect up the earth cable last, as there is otherwise a risk of short-circuits. Temporary decommissioning of engines Temporary anti-corrosion protection according to MAN works norm M 3069 is required for engines which are to be put out of service for fairly long periods. -
Page 32: Technical Data
Technical data Model D 0824 LE 201 Design in-line vertical Cycle 4-stroke Diesel with turbocharger and intercooler Combustion system Direct injection Turbocharging Turbocharger with intercooler Number of cylinders Bore 108 mm Stroke 125 mm Swept volume 4 580 cm Compression ratio... - Page 33 Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 9 ltr. 13 ltr. Oil change quantity (with filter) 14,5 ltr. Oil pressure during operation (depen- must be monitored by oil pressure moni- ding on oil temperature, oil viscosity tors / gauges class and engine rpm) Oil filter...
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Page 34: Troubleshooting Table
Troubleshooting table Fault Engine does not start, or starts only with difficulty Engine starts but does not reach full speed or stalls Engine idles out of true when warm, misfiring Engine speed fluctuates during operation Power output unsatisfactory Coolant temperature too high, coolant being lost Lube oil pressure too low Lube oil pressure too high Black smoke accompanied by loss of power... - Page 35 Troubleshooting table Fault Engine does not start, or starts only with difficulty Engine starts but does not reach full speed or stalls Engine idles out of true when warm, misfiring Engine speed fluctuates during operation Power output unsatisfactory Coolant temperature too high, coolant being lost Lube oil pressure too low Lube oil pressure too high Black smoke accompanied by loss of power...
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Page 36: Index
Index Air filter ........Maintenance and care .