Man D 0836 LE 201 Operating Instructions Manual
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Man D 0836 LE 201 Operating Instructions Manual

Man D 0836 LE 201 Operating Instructions Manual

Industrial diesel engines
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  • Page 3 Operating Instructions − MAN Industrial Diesel Engines...

  • Page 5: Preface

    You can find the approved products in the internet under: −http://www.man-mn.com/ " Products & Solutions " E-Business− 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.

  • Page 6: Instructions

    Flat seals / gaskets can be fitted properly only if the following points are ob- served: D Use only genuine MAN seals / gaskets D The sealing faces must be undamaged and clean D Do not use any sealing agent or adhesive − as an aid to fitting the seals a little grease...

  • Page 7: Table Of Contents

    ..........Engine views D 0836 LE 201 / 203 .

  • Page 8: 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 9: 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 10: Safety Regulations

    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. D Keep vicinity of engine, ladders and stairways free of oil and grease.
  • Page 11 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.
  • Page 12 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 13 Safety regulations D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground. Caution: The drinking water supply could be contaminated. D Filter elements are classed as dangerous waste and must be treated as such. Coolant D Treat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.

  • Page 14: Commissioning And Operation

    Commissioning and operation Engine views D 0836 LE 201 / 203...
  • Page 15 Commissioning and operation À Fan hub Á Fuel filter  Fuel prestrainer à Injection pump Ä Starter Å Oil filter Æ Combustion air pipe from intercooler Ç Fuel pump È Oil drain plug É Oil filler neck Combustion air pipe to intercooler Alternator Tensioning pulley Oil dipstick...

  • Page 16: First Commissioning

    When putting a new or overhauled engine into operation for the first time pay attention to the “Installation instructions for MAN industrial Diesel engines” without fail. 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

    For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”. You can find the approved products in the internet under: −http://www.man-mn.com/ " Products & Solutions" E-Business− Checking oil level Check engine oil level only approx. 20 minutes after the unit has been 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: Setting The Digital Speed Governor

    Commissioning and operation Setting the digital speed governor Note: All information in this chapter is an extract from the operator’s manual from the manufacturer, GAC Engine Governing Systems, or the importer, HÜGLI TECH LTD SWITZERLAND. Caution: The basic setting of the governor was made at the factory and can- not be changed.
  • Page 20 Commissioning and operation Access to SETUP mode Access to SETUP mode D Press SETUP button à until the RUN / RUN / SETUP LED À starts to flash. GAIN SETUP STABILITY FAULT D Key in password (0000, i.e. 4x the fig- DERIVATIVE ure zero) and press the ENTER button Æ...
  • Page 21 Commissioning and operation Setting parameters Caution: When setting the parameters: Always leave SET–UP mode by pressing the RUN button, as the changes will otherwise be lost. Gain (sensitivity) MENUE Input: Menue 0, button 1 Every time the MENU button is pressed the next gain point is selected and shown by the relevant LED in the LED bar.
  • Page 22 Commissioning and operation Derivative (dead time compensation) MENUE Input: Menue 0, button 3 In certain cases it may be necessary to adjust the dead time compensation (DERIVATIVE) too. If the engine speed is hunting quickly even though GAIN has been set low, the DERIVATIVE can be reduced by tapping the –...
  • Page 23 Commissioning and operation Resetting to the works settings: a) Select SETUP mode, see page 60. b) Ensure that no menu is activated, i. e. that all LEDs are off. c) Key in figures 1-2-3-4 and confirm with the ENTER key. d) If the works settings are reactivated the LEDs 4-3-2-1 will flash.

  • Page 24: Operation Monitoring System

    Commissioning and operation Operation monitoring system Caution: Do not overload the engine. Do not exceed the maximum permissible engine tilt.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.

  • Page 25: Maintenance And Care

    For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”. You can find the approved products in the internet under: −http://www.man-mn.com/ " Products & Solutions" E-Business− Refilling with oil Danger: The oil is hot− risk of scalding. Do not touch the oil drain plug with bare fingers.
  • Page 26 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! Refill with fresh engine oil at the oil filler neck À.
  • Page 27 Maintenance and care Changing oil filter Caution: Used oil and oil filters are classed as dangerous waste. Observe safety regulations to prevent dam- age to the environment. A tape wrench is a suitable tool for un- screwing the disposable filter box. Use a vessel of sufficient size to ensure that the oil does not overflow Danger:...

  • Page 28: Fuel System

    Coolants for MAN Diesel Engines”. You can find the approved products in the internet under: −http://www.man-mn.com/ " Products & Solutions" E-Business− Injection pump No alterations must be made to the injection pump. If the lead seal is damaged the war- ranty on the engine will become null and avoid.
  • Page 29 Maintenance and care Fuel filter (Single and parallel box−type filter) Changing fuel filter Only when the engine is swiched off. D Loosen filter with tape wrench and re- move it D Wet seal on new filter with fuel D Screw on filter by hand D Bleeding the fuel system D Check filter for leaks Caution:...
  • Page 30 Maintenance and care Cooling system Danger: Draining hot coolant involves a risk of scalding. Draining the cooling system Caution: Drain coolant into a suitable con- tainer and dispose of it in accord- ance with regulations. Drain coolant as follows when cooling sys- tem has cooled down D Briefly open cap (large cap) on the filler neck of the expansion tank for pressure...
  • Page 31 Coolants for MAN Diesel Engines”. You can find the approved products in the internet under: −http://www.man-mn.com/ " Products & Solutions" E-Business− Coolant must be added at the filler neck only (large cap). Do not put cold coolant into an engine which is warm from operation.

  • Page 32: Air Filter

    Maintenance and care Air filter À Connection for contamination gauge Á Filter housing  Retainer à Filter cartridge Ä Hex nut Å Lid Æ Dust collector Service only when engine is switched off. Dust collector The dust collector must be emptied at reg- ular intervals.
  • Page 33 Maintenance and care Contamination gauge À Red display cylinder Á Return knob In the window a red field appears which grows in size as the contamination in- creases. If the red field is fully visible in the window, the air filter is contaminated and must be cleaned or changed..
  • Page 34 Maintenance and care Cleaning the cartridge Caution: The filter cartridge should normally be changed. Clean it only in emergencies (e.g. when no replacement is available). Blowing out (wear goggles) To do this fit a pipe to the compressed air gun. The end of the pipe should be bent by approx.
  • Page 35 Maintenance and care Safety cartridge When the main cartridge is being serviced the safety cartridge remains in the filter hous- ing. The engine must not be run without the main cartridge. Safety cartridges must be neither cleaned nor re−used. Safety cartridges must be changed: −...

  • Page 36: Ribbed V-Belt

    Maintenance and care Ribbed V-belt Checking condition The ribbed V-belt is maintenance free. D Check V-belts for cracks, oil, overheat- ing and wear D Change demaged V-belts Checking tension The ribbed V-belt is always kept at the correct tension by the tensioning device (arrow).
  • Page 37 Maintenance and care Exchanging the ribbed V-belt D Fit suitable tool on the square head D Press back V-belt tensioner D and remove V-belt outwards from the tension pulley Assembly: D Place ribbed V-belt on the pulley of the crankshaft, the alternator and the cool- ant pump D Press back V-belt tensioner D Place V-belt on the tension pulley, re-...

  • Page 38: Turbocharger

    Maintenance and care Turbocharger At every engine oil change check the oil pipes for leaks and constrictions. Furthermore, a regular check should be kept on charge air and exhaust gas pipes. Any leakages should be attended to at once because they are liable to cause over− heating of the engine.

  • Page 39: Alternator

    D Do not operate the alternator without battery connection! 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. The works norm can be obtained from our After−Sales Service department Nuremberg...

  • Page 40: Technical Data

    Technical data Model D 0836 LE 201 / 203 Design in−line vertical Cycle 4−stroke Diesel with turbocharger and in- tercooler Combustion system Direct injection Turbocharging Turbocharger with intercooler Number of cylinders Bore 108 mm Stroke 125 mm Swept volume 6 870 cm...
  • Page 41 Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 22 l 28 l Oil change quantity (with filter) 30 l 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...

  • Page 42: Index

    Index Air filter ......32–35 Ribbed V-belt ......36–39 Alternator .

This manual is also suitable for:

D 0836 le 203

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