Man D 0836 LE 401, Operating Instructions Manual

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Page 3: ...3 Operating Instructions MAN Marine Diesel Engines ...

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Page 5: ...roved fuels lubricants and coolants are used Note Only use fuel coolants and lubricants in accordance with MAN s regulations otherwise the manufacturer s warranty will not apply 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 It is i...

Page 6: ... operation due to the sew ing machine effect in particular if they are used between parts with different rates of lin ear expansion under heat e g aluminium and cast iron and leaks may then occur Example the cap of the front crankshaft seal If a sealing agent or an adhesive is used here the flat seal will move inwards in the course of time as a result of the different expansion rates of the materi...

Page 7: ...ws D 0836 LE 401 18 First commissioning 20 Commissioning 22 Starting 23 Operation monitoring system 24 Tachometer CAN Master 25 Shutting down 56 Maintenance and care 57 Lubrication system 57 Fuel system 60 Cooling system 64 V belts 67 Alternator 68 Temporary decommissioning of engines 68 Technical data 70 Troubleshooting table 72 Index 74 ...

Page 8: ...e 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...

Page 9: ...Declaracion 9 ...

Page 10: ...em in the appropriate spaces The engine type plates are on the crank case Typ 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 Aktiengesellsc MAN Nutzfahrzeuge Aktiengesellschaft Altitude m Rating BHP Job No Rating kW Speed rpm Serial No Model Year 0219 Aufstellhohe m uNN Lei...

Page 11: ...n 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...

Page 12: ... is running do not get too close to the rotating parts Wear close fitting clothing D Do not touch the engine with bare hands when it is warm from operation risk of burns ËË D For safety reasons a separate functioning red emergency stop button for each engine must be installed at every bridge the engine must stop immediately when the button is pressed once D Exhaust gases are toxic Comply with the ...

Page 13: ...pter entitled Maintenance and Care ËËË D Neither 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 D Fuel is inflammable Do not smoke or use naked lights in its vicinity The tank must be filled only when the engine is switched off D When using compressed air e g for cleaning...

Page 14: ... 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 D Have the engine maintained at the specified intervals D Do 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 D Never put cold...

Page 15: ... precautions to ensure that no oil or Diesel fuel gets into the drains or the ground 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 D When disposing of spent coolant comply with the regulations of the relevant local auth orities ...

Page 16: ...tc or wear protective gloves D Clean 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 D After washing apply a fatty skin cream to the skin D Change oil soaked clothing and shoes D Do not put oily rags into...

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Page 18: ...Commissioning and operation 18 Engine views D 0836 LE 401 11 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 ...

Page 19: ...r 4 Starter motor 5 Oil filler neck 6 Oil dipstick 7 Oil filter 8 Injection pump 9 Prestrainer 10 Fuel filter 11 Water pump engine coolant circuit 12 Crankcase breather 13 Hand primer 14 Generator 15 Raw water pump 16 Oil drain plug 17 Heat exchanger 18 Turbocharger liquid cooled ...

Page 20: ...ut gradually Note Use only approved fuels lubricants etc see brochure Fuels lubricants etc Otherwise 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 wit...

Page 21: ...s a risk of frost drain the raw water pump 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 with out oil Pour oil into engine via filler neck see page 58 For the quantity required see Technical Data ...

Page 22: ... approx 20 minutes after the unit has been switched off D Pull out dipstick arrow D wipe it with a clean lintfree cloth D and push it in again up to the stop D Pull 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 o...

Page 23: ...periods it may cool down and thus start to emit white or blue smoke We therefore recommend that you do not let the engine idle for more than 5 minutes It is well known that with any internal combustion engine wear is higher during idling Prolonged idling is harmful to the environment Caution Do not overload the engine Do not exceed the maximum permissible engine tilt If faults occur find their cau...

Page 24: ...v counter with integrated digital operating hours counter for description see page 39 CAN Bus round instruments rev counter with information display and buttons D Rev counter 0 4000 rpm with integrated LCD display for the following parameters and buttons for paging Engine oil pressure Gearbox oil pressure Engine coolant temperatur Engine oil temperature Engine exhaust temperature Charge air temper...

Page 25: ...stru ment is thus easy and uncomplicated LC Display Push button key Main Functions The main functions of the VDO Ocean Link can be called by pressing the push button key Each time the key was pressed the next measured value is displayed Engine oil pressure Charge air temperature Gearbox oil pressure Charge air pressure Coolant temperature Load Engine oil temperature Running time Exhaust gas temper...

Page 26: ...ettings The basic settings necessary for perfect operation can be selected in the settings These are obtained by pressing and holding the push button key while switching on the power supply of the display Display Units Selection of display unit Screens on off Selection of display Simulator Mode Activation of simulator mode Exit Setup Ending the setting menu In order to change a value e g from NO t...

Page 27: ...value is displayed NO No change in the setting are made Aktivation of the simulation mode simulator mode Select here whether the simulation mode is to be switched on YES The simulation mode is switched on The display now generates random values for all measuring channels and displays these The measured values are also transmitted to the bus instruments NO The simulation mode is switched off Please...

Page 28: ... an alarm not only the relevant LED but also the integrated buzzer is activated In the event of a pre alarm only the LED of the associated measuring point flashes In the event of a master alarm the Alarm status LED is also activated If the alarm is a shutdown or slowdown alarm the corresponding status LED Engine slow down or En gine stop also lights up When the acoustic acknowledgement Horn Quit k...

Page 29: ...ree buttons with which various functions such as Alarm Quit are poss ible The buttons have the following functions Standard function Acoustic quit or switch off of the internal horn All other monitoring devices in the system are quitted too Test function Holding the key for at least 5 seconds activates the built in buzzer Standard function Visual quit i e all flashing alarms stop flashing but rema...

Page 30: ...l temperature The device distinguishes between the following types of alarm error messages D Preliminary alarm the corresponding light emitting diode flashes D Main alarm the corresponding light emitting diode flashes light emitting diode Alarm flashes In the case of an engine slow down alarm Engine slow down also flashes In the case of a stop alarm Engine stop also flashes D Sensor fault the corr...

Page 31: ... Function test of the warning lamps If there is no alarm the warning lamps can be tested When the Test key is pressed all the warning lamps must light up Dimming All the alarm LEDs are automatically dimmed depending on the ambient luminosity This function is performed by a photoelement integrated in the front panel Horn test If the Clear horn key is pressed for approx 5 seconds the fitted buzzer a...

Page 32: ...rpm Oeltemp Motor 120 C Ladelufttemperatur 64 C Kuehlwassertemp Motor 83 C Oeldruck Motor 4 3 bar M 1 A 3 ALARMS Men PAGE RESET Prg Engine run System Fail Alarm MAN MARINE DIESEL TYP MMDS LC TEST 51 27720 7015 Representation of monitor pages The analog engine data provided by the MMDS is distributed on 4 monitor pages On each page the current engine speed is displayed in the top line The 1st page ...

Page 33: ... C The pages are scrolled using the PAGE key Each time the key is pressed the screen moves up to the next page After page 4 page 1 appears again For the display of current alarms and warnings an alarm screen has been included This is called up using the ALARMS key If there is no alarm the message no message appears on the screen A1 no message If an alarm is activated the device switches automatica...

Page 34: ...shes At the same time the monitor switches automatically to the alarm screen The new alarm is entered in the first line as a flashing message The alarms that would be issued if the engine is stopped but the engine ignition is on e g lack of oil pressure are suppressed disabled until the green LED Engine run lights up This occurs approx 8 seconds after ignition engine speed has been reached When th...

Page 35: ...ternal horn All other monitoring devices in the system are acknow ledged via the serial bus Test function Holding the key for at least 5 seconds activates the built in buzzer PRG menu function adopt currently selected setting Prg Programm Visual Quit Test Standard function visual acknowledgement i e all flashing alarm texts in the currently visible alarm screen switch to constant representation if...

Page 36: ...analog engine data from which the alarm screen was originally cal led Special function Key enables setting of the LCD contrast with simulta neous pressing of the keys TE S T or RESET ALARMS Standard function Calling up the alarm screen the five alarms or war nings last issued and still present are displayed At the top left of the mo nitor is the code A1 If there are more than 5 messages issued the...

Page 37: ...lection can be cancelled using the Escape function menu key ALARMS Men All other previously made set tings are not influenced by this Selection of language and units When the menu is opened the current settings are shown highlighted in black A flashing selection cursor marks the language currently set e g English Englisch German French Italian Spanish US GB D F I E The selection cursor can be move...

Page 38: ...splay function In the event of an input error you can use the function back to repeat the input The selection cursor jumps back to the initial position lan guage selection Setting the time First the selection cursor must be placed in the second last line To do so the current language and unit settings are confirmed each time with the key Prg The selection cursor can now be positioned using the key...

Page 39: ...tral unit is active engine ignition on the date and time are overwritten and the following message appears briefly in the display LOAD MMDS SYSTEM TIME If the central unit is switched off engine ignition off nothing is changed and the following message appears NO MMDS TIME RECEIVED The selection cursor then jumps back to the second last line to the item exit Ship specific alarms There is the possi...

Page 40: ...th two variants of the accelerator control system Marex SB or Mini Marex both from Bosch Rexroth 1 Marex SB This control system has plug connections specially made for MAN It is a low cost variant without trolling function and has control electronics for two engines in the engine room Both the engine speed and the gearbox position forward neutral reverse are preset via the accelerator position Max...

Page 41: ...NCHRO Passive Bridge COMMAND ALARM SYNCHRO Active Bridge Switch on and bridge request When the supply voltage has been switched on all correctly functioning command initi ators are in the lamp test status all lamps and buzzers on Command can be requested at any bridge by pressing the button once When the button has been pressed at one command initiator the lamp test status at all command initiator...

Page 42: ...es slowly Command lamp flashes fast All lamps on As soon as a bridge is activated the gearbox neutral position and the idling speed are triggered Commands can then be given from the active bridge Note on command initiator for twin engines In this case both accelerators must be put in neutral The command lamps are allocated to the function of the relevant accelerator port starboard Note on faults C...

Page 43: ...mmand is assumed if the button is pressed again Position comparison mode In the position comparison mode the accelerator position of the active command initiator must not diverge by more than 30 from that of the active command initiator In addition the range too forward neutral reverse must be the same before a change of bridge can be effected The button does not have to be pressed a second time T...

Page 44: ...dling speed is not sufficient for this Zum To switch this function on and off press the button on the active bridge Danger Die The Increased idling speed function cannot be used unless it has been set If the function has been set the Synchronisation function cannot be switched off Synchronisation If in twin engine systems the positions of the port and starboard accelerators at the ac tive command ...

Page 45: ...eutral lock position À In this position the gearbox clutch is disengaged and the power unit is idling Each time the Neutral position is reached the control system indicates this acoustically by means of a short beep tone Gearbox forwards reverse lock position Á In this lever position two different functions are possible 1 Standard function The gearbox clutch is engaged to Forwards or Reverse the p...

Page 46: ...weakly via LED L1 and indicates that the control system is being supplied with voltage The key serves to take over commands onto the relevant control stand The key has two other additional functions Additional function Warming Up The expression Warming Up means engine running without shifting gear which en ables for example warm up of a cold power unit across the entire speed range The gearbox clu...

Page 47: ... function the Warming Up function stops automatically when position À neutral When position Á gearbox forwards reverse is reached again the gearbox clutch would be engaged again Additional function switch error message to mute The acoustic signal transmitter which is activated for some alarms can be disabled at the relevant control stand by pressing the Command takeover key However this does not d...

Page 48: ...inuous tone at the active control stand this is not a fault alarm but a warning The second command master must then be set into the Neutral position to terminate the warnings The engine speed of the relevant command master is kept at idling speed during this period While the control system is in the function Synchronisation the engine speeds of both power units can the only be changed using the co...

Page 49: ...ition The engine idles but due to the greatest possible clutch slip 100 slip is not yet able to turn the propeller shaft or can do so only very slowly If the command master lever is moved further towards position  the clutch slip drops continuously and at the same time the engine speed rises When position  is reached the clutch is in the smallest possible slip position 0 slip frictional connecti...

Page 50: ... stands weakly lit up only visible in darkness Acoustic signal transmitter sounds with slow intermittent tone on all control stands 2 Command request The command can be requested at any control stand The control levers of the command master on the requesting control stand must be set at the Neutral position Command master calibration and enable of control stands must have been carried out Otherwis...

Page 51: ... change from one control stand to another can only take place if the ever of the requesting command master is either in the neutral posi tion or in the same travel direction position as thelever of the command master that is in command The command change for this variant takes place in two steps 1 step Command request on the selected control stand Execution Set the control lever of the command mas...

Page 52: ...mand change The command change takes place in one step Command request on the selected control stand Execution Press Command key white to take over the command on this con trol stand Consequence The Command display on the selected control stand immediately shows continuous ligh The command is immediately at this control stand and the control system instantly runs the lever position of the command ...

Page 53: ... One main fuse with 20 A is fitted at the engine these blow in the event of overcurrent or short circuit If the fuse as blown the engine can no longer be started The fuse can be reset by the operator using the keys fitted Attaching the fuse at the starter Fuse ...

Page 54: ...erminal box with the keys for fuse F5 F6 F7 Charge control lamp on the terminal box A charge control lamp is fitted on the ter minal box This should only light up at Ignition on As soon as the engine is running this lamp should go out If it lights up when the engine is running there is a defect in the dynamo The battery is no longer being charged The monitoring system reports the fault Failure of ...

Page 55: ...larm horn and the integrated buzzer D Flashing light off transition to continuous light test of light emitting diodes Switches off the flashing signal of the relevant warning lamp i e the flashing light switches to continuous light Before the flashing signal is cleared the alarm horn must be switched off D Reset Clears the alarm message red warning lamp goes out Requirement for clearing an alarm m...

Page 56: ...nsor is defective The measurement point of the defective sensor flashes with the same frequency as Sensor failure D Speed sensor failure Defective engine speed input D Remote slow down Remote reduction of speed Alarm at other engine The defective engine reduces the intact engine This prevents a curving manoeuvre in the case of an alarm Shutting down Do not switch off engine immediately operation a...

Page 57: ...ing temperature remove the oil drain plugs on the oil sump and the oil filter bowl and allow the old oil to drain off completely Use a vessel of sufficient size to ensure that the oil does not overflow Since the oil drain plug on the engine oil pan and on the gearbox is frequently not accessible an electric oil drain pump may be fitted to or in the vicinity of the engine Open cap on oil drain hose...

Page 58: ... low speed Caution If no oil pressure builds up after approx 10 seconds switch off the engine immediately Check oil pressure and check that there is no oil leakage Then shut down the engine After about 20 minutes check the oil level D Pull out dipstick arrow D wipe it with a clean lintfree cloth D and push it in again up to the stop D Pull out dipstick again The oil level should be between the two...

Page 59: ...When the engine is at operating tempera ture open the cover of the oil filter housing until the O ring is visible The oil in the oil filter drains off into the oil sump The housing cover can removed after about 12 minutes Unscrew cover À and remove filter car tridge  Claen inside filter bowl Insert new filter cartridge  and refit cover À with new sealings Á Obseve tightening torque for cover À A...

Page 60: ...se any additives to im prove flow properties in winter Injection pump Neither the injection pump nor the control unit must be modified in any way If the lead seal is damaged the warranty on the engine will become null and avoid Faults We urgently recommend that you have faults in the injection pump rectified only in an au thorised specialist workshop Cleaning fuel pre cleaner Strip the fuel pre cl...

Page 61: ...e classed as dangerous waste and must be dis posed of accordingly Change over fuel filter Where the changeover type filter is in stalled the servicing procedure is for the filter side requiring to be shut off with the engine running During continuous oper ation position the selector lever that both filter halves are in operation Caution Do not leave selector lever in any intermediate position beca...

Page 62: ...d of accordingly Bleeding the fuel system Note To bleed the fuel system switch on the ignition so that the safety relay will be open An arrow on the filter head indicates the direction of fuel flow D Unscrew bleed screw of first filter in direction of flow by one or two turns D Actuate tappet of hand primer until fuel emerges without bubbles D Screw in and tighten plunger on hand pump D Close blee...

Page 63: ...e union nut in one pressure pipe at the injection nozzle by approx 1 2 revolution D Turn engine over with starter motor un til fuel is seen to emerge Caution The pipes contain fuel Use a rag to catch any fuel that emerges Comply with safety regulations and official regulations D Tighten the union nut Note First tighten the nuts to 10 Nm and then by an angle of 60_ Violent tightening will destroy t...

Page 64: ...ng 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 To let off pressure briefly open cap large cap on filler neck of expansion tank D Remove drain plugs from oil cooler housing Á and turbine housing  D Then take off the cap D Drain coolant into a container of ad equate size D R...

Page 65: ...e cap Do not put cold coolant into an engine which is warm from operation Ensure that the ratio of water to anti freeze is correct D Remove cap À large cap D Set heating if fitted to full output open all shut off valves open bleeders if fitted D Slowly fill up with coolant via filler neck on expansion tank until fluid level has reached the lower edge of the filler neck D Refit cap À D Let engine r...

Page 66: ...p Danger If in an exceptional case the coolant level has to be checked in an engine that has reached operating temperature first carefully turn the cap with safety valve to the first stop let off pressure then open carefully Note Don t open the cooling system when the engine is at operating temperature This causes a pressure loss in the cooling system Coolant pressure in the expansion tank is only...

Page 67: ...cator to move upwards If pressure is maintained after the spring has disengaged a false reading will be ob tained Reading of tension D Read of the tensioning force of the belt at the point where the top surface of the indicator arm À intersects with the scale D Before taking readings make ensure that the indicator arm remains in its position If the value measured deviates from the setting value sp...

Page 68: ...ry or pole terminals or the cables D If durig operation the battery charge lamp suddenly lights up stop the engine im mediately and remedy the fault in the electrical system D Do not run the engine unless the battery charge control is in satisfactory order D Do not short circuit the connections of the alternator with those of the regulator or said connections with ground not even by briefly bringi...

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Page 70: ...kW 450 hp at 2600 rpm D 0836 LE 402 265 kW 360 hp at 2400 rpm Firing order 1 5 3 6 2 4 Valve clearance cold engine Intake 0 50 mm Exhaust 0 60 mm Valve timing Intake opens 18 before TDC Intake closes 32 after BDC Exhaust opens 63 before BDC Exhaust closes 29 after TDC Fuel system Injection pump Bosch distributor type injection pump VP44 Governor Electronic Diesel Control EDC Model MS6 4 Start of d...

Page 71: ...x 24 l 28 l Oil change quantity with filter 30 l Oil filter Full flow filter with two paper filter ele ments Engine cooling system Liquid cooling Coolant temperature 80 90 C temporarily 95 C allowed Coolant filling quantity 58 l Electrical equipment Starter 24 V 4 kW Alternator 28 V 55 A ...

Page 72: ...densation in fuel D D D D Air filter clogged D Electric circuit interrupted D Batteries flat D Starter solenoid switch defective D D D D D Start of delivery not correct incorrectly set D Injection nozzles clogged D Internal damage to engine piston seized possibly caused by water in fuel D D D Fuel quality not in accordance with specifications or fueled severely contaminated D Lower idling speed se...

Page 73: ...expansion tank radiator defec tive or leaking D Temperature gauge defective D Coolant pipes leaking blocked or twisted D Oil level in sump too low D Engine temperature too high D Oil filter clogged D D Oil pressure gauge defective D D Selected oil viscosity not suitable for ambient temperature oil too thin D Oil in sump too thin mixed with condensation or fuel D Engine cold D D Engine coolant or i...

Page 74: ...ameplates 10 O Operation monitoring Charge control lamp on the terminal box 54 Display device MMDS D08 L 28 Drive lever control system Mini Marex 45 Main fuses for on the engine 53 Main fuses on terminal box 54 Terminal box in the engine room interface with light emitting diodes keys 55 Operation monitoring system 24 49 MMDS L display unit 30 MMDS LC display unit 32 P Parallel fuel filter 61 R Raw...

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