Man V12-1800, Installation Instructions Manual

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Page 3: ...fety and safety at work regulations must also be observed Caution MAN is only liable for material defects when these installation instructions have been observed On request and against payment MAN wil...

Page 4: ...of power by propshafts 32 Combustion air system and charging 38 Exhaust system 40 Cooling system 45 Fuel system 50 Propeller system 54 Auxiliary power take off 58 Electrical system 59 Electrical preh...

Page 5: ...e read the operating instructions carefully and familiarize yourself with the critical points If you are unsure ask your MAN representative D For reasons of safety we recommend you attach a notice to...

Page 6: ...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 scalding Do not get too cl...

Page 7: ...sed to extreme stresses The high precision technology requires the utmost cleanliness during all work on the fuel system Even a particle of dirt over 0 2 mm can lead to the failure of components D Do...

Page 8: ...asic 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 D Avoid prolonged or repeated skin cont...

Page 9: ...rail on the rail and on the cylinder head to the injector Keep away from the engine when it is running D Risk of injury When the engine is running the lines are constantly under a fuel pressure of up...

Page 10: ...eakage or damage to the fuel system D Do not spray the high pressure cleaner direct onto the electric components or alternatively keep them covered D Do not carry out any welding or sanding work in th...

Page 11: ...es off when connections are loosened from possible over coating these chippings must be carefully removed before finally loosening the screw connection D The connection openings of all parts removed f...

Page 12: ...Planning of engine installation 10 V12 1800 1 2 3 4 5 V8 1200 6 7 8 9 4 10 11...

Page 13: ...ndividual components to be observed when installing engines Each of these components has a connection to a ship side component Their correct installation contributes to the trouble free operation of t...

Page 14: ...e hardness of the resilient mounts depends on the setup of the drive line free standing or flange mounted gearbox Wiring diagrams Wiring diagrams are available specially adapted for the needs of the s...

Page 15: ...decking or hatch to facilitate the lifting out of the engines in the event of repair It must be possible to carry out the following tasks in the engine room on the engine and gearbox without restricti...

Page 16: ...tions An oil drain for the engine and gearbox can be supplied optionally fitted left and right An electrical oil suction removal and filling pump can be connected via quick release couplings D Filling...

Page 17: ...ternator 13 And coolant pump D Visual inspection and retightening of bolts and hose connections Distance to bulkhead D 350 mm Removing the cylinder head cover 14 to D Adjustment of valve clearance 16...

Page 18: ...ough seas must be safely absorbed D Hull torsion caused by motion of the sea and load must not be transmitted to the engine The contact area between the engine foundation and the hull should be as lar...

Page 19: ...113 litres 120 kg Maximum permitted angle of inclination for engine If the engine is to be installed at an inclination on its longitudinal axis the maximum permitted angle of inclination must not be e...

Page 20: ...gine foundation for engines with flange mounted gearboxes Easy height adjustment of the mounts Due to these various requirements the resilient mounts must be carefully adapted For this reason MAN has...

Page 21: ...stallation drawing Engine with free standing gearbox The figure shows a V12 1800 example with a free standing gearbox The engine brackets are installed The corresponding resilient engine mounts are de...

Page 22: ...free standing gearbox 51 96210 7050 70 The installation drawings have information on the dimensions of the mounts and the drilling pattern for the foundation Installation of the mounts D Place drive...

Page 23: ...sions of the mounts and the drilling pattern for the foundation Installation of the mounts D Place engine with mounts onto foundation D Align the drive train after allowing the mounts to settle for 48...

Page 24: ...and high power outputs the temperature of critical components charge air pipes compressor housing exhaust manifold is at its highest and thus the heat output is at a maximum However this effect is com...

Page 25: ...engine room has a thorough circulation of fresh air The following criteria will help you in selecting effective fans 1 Fans with a 24V constant voltage power supply 160 mm to 300 mm 2 Fans with an al...

Page 26: ...tilising the air stream produced from forward motion Caution Water spray and splash water must not be allowed to reach the engines Water ingress would lead to the total loss of the engine A Free cross...

Page 27: ...able lifting equipment that is not strong enough for the load may result in serious accidents injury Make sure ropes and chains do not pull crookedly on the crane hooks There are 4 crane hook lugs on...

Page 28: ...engine mount see page 20 Torsional vibration analysis The forces of gas and inertia from the engine can cause vibration of the entire drive line In order to determine the resonance in terms of positio...

Page 29: ...silient coupling is to be provided between the engine and the gearbox This has the function of decoupling vibrations between the engine and the drive train gearbox propeller shaft and propeller In thi...

Page 30: ...ial play before and after the installation of components using a magnetic mounting fixture with dial indicator If both measurements do not match or if the crankshaft bounces back after being pressed c...

Page 31: ...the correct height for the gearbox output flange This ensures that the propeller shaft can be correctly centred Note A resilient propeller shaft coupling between gearbox output flange and propeller sh...

Page 32: ...her gearbox output flange and propeller shaft flange are flush in relation to each other Check for parallelism of flanges D Join propeller shaft flange and gearbox output flange together D Slide feele...

Page 33: ...re than 2 x 0 5 mm 1 mm Angle offset means that the centre lines of 2 associated flanges are not parallel Flange e g gearbox output Flange e g propeller shaft Angle offset Angle offset max 0 1 mm with...

Page 34: ...by propshafts 32 Drive line consisting of engine highly resilient coupling propeller shaft and gearbox 1 2 3 4 5 Drive line consisting of engine resilient coupling with flange bearing propeller shaft...

Page 35: ...ilient coupling figure at top left The highly resilient coupling connected to the engine s flywheel allows working angles of max 3 Engine Resilient engine mounts Highly resilient coupling see page 34...

Page 36: ...s installed at the engine s flywheel The coupling can only be installed if the engine is equipped with the corresponding flywheel for propeller shaft couplings It allows permissible propeller shaft wo...

Page 37: ...he complete compensation of the irregular motions the following requirements must be met D Identical running angles at both joints 1 2 D Both inner joint forks must lie in a plane D Input and output s...

Page 38: ...arbox longitudinal axis in the plan view 1 mm Auxiliary equipment consisting of two alignment rods can be used to obtain the same working angle for a V configuration Such auxiliary equipment is illust...

Page 39: ...oints and splined sections may be damaged The propeller shafts are to be arranged so that the splined section is protected from dirt and moisture Usually what this mean is that they are to be installe...

Page 40: ...turbocharger After passing through the air filter the combustion air is pre compressed by the low compression stage turbocharger and cooled by the intercoolers The high compression stage turbocharger...

Page 41: ...ilters Caution If any dust producing work is to be performed on the ship after the engine has been installed please take measures to protect the air filters from this dust Vacuum downstream of air fil...

Page 42: ...write off that is not covered by the MAN warranty It is not permissible to provide a single common exhaust system for several engines In the case if multi engine layouts a separate exhaust system for...

Page 43: ...rom the resilient engine mounting and isolate the engine vibrationally from the exhaust system Either heat resistant hoses corrugated hoses made of silicone or bellow expansion joints can be used for...

Page 44: ...ea water is injected into the exhaust pipe and mixed with the exhaust gas Schematic drawing of sea water injection example Sea water Exhaust gas Baffles with obtuse angle of incidence for water flow B...

Page 45: ...is omitted there can be a build up of pressure in the exhaust system when the ship is stationary or moving at low speed until this pressure exceeds the water pressure below the ship and then escapes a...

Page 46: ...D High engine room temperatures Hot non insulated exhaust pipes heat up the engine room considerably The quantity of heat emitted increases by the surface temperature raised to the power of 4 e g sur...

Page 47: ...er The cooling system on all MAN engines is designed for seawater temperatures of up to 32 C 305 K 1 2 3 4 4 5 6 7 Expansion reservoir Charge air cooler high compression stage Seawater outlet Intercoo...

Page 48: ...tured as a single casting The sea water enters through a grille with large openings between the bars In order to assist the inflow into the sea water inlet pipe to the engine the back of the scoop mus...

Page 49: ...lowing approximate values apply to the filter basket Mesh size max 3 mm Surface approx 10 times as large as the inlet cross section Positioning of sea water filter If possible directly above the sea v...

Page 50: ...42 A hose with a 4 inch diameter is used to connect to the ship side piping Measuring points for commissioning For the commissioning process there are measuring points installed at the inlet and outle...

Page 51: ...als according to their electric potential starting with the most noble platinum down to the most non noble magnesium The further two metals are apart in this list the greater the problems to be expect...

Page 52: ...of delivery Fuel tank Fuel return from engine to fuel tank The fuel flows from the tank through the fuel prefilter with water separator to the fuel system on the engine Surplus fuel is returned back...

Page 53: ...rain plug with left hand thread Filter bowl Filter cartridge Note Note the lever position of the 3 way valve Handle in position A continuous operation both filter halves switched on B left side switch...

Page 54: ...contaminated When installing the fuel pre filter in the engine room care should be taken that there is adequate space to trap the separated out water and to change the filter cartridge Mounting bolts...

Page 55: ...nnection Threaded connector M22x1 5 The fuel return in the tank must always be under the fuel level Caution The fuel pressure is constantly monitored at measuring point If the max permissible suction...

Page 56: ...reached Operating point The ship must thereby be loaded as follows Equipment on board Fuel tanks filled Water tanks filled Engine power curve Propulsion resistance curve Speed power reduction curve Op...

Page 57: ...eller that is too big Power consumption of propeller too small The propeller cannot absorb and transmit the power available from the engine The engine speed is significantly higher than the rated spee...

Page 58: ...possible torque full load currently requested which can be delivered by the engine at a certain rpm The engine always delivers as much torque as the propeller can take at that moment Note This is calc...

Page 59: ...0 rpm the engine cannot output more power A reserve of power of 63 remains available e g for acceleration Example 2 The load indicator shows 80 at a rated speed of 2300 rpm This means Because the prop...

Page 60: ...en the auxiliary power take off is closed off with a blind flange Data on power take off Direction of rotation viewed towards flywheel Counterclockwise Speed 1 3 x Engine speed Max transmittable torqu...

Page 61: ...round cable Batteries Each engine has a separate battery for the starter 24V DC consumers are to be supplied by their own batteries Starters All MAN ship engines have starters with 2 poles For this re...

Page 62: ...5 4 min 1 2 max 5 7 min 1 5 max 6 0 Starter short circuit current at 20 C A 2370 1620 2370 1620 2370 1620 2370 1620 2370 1620 Minimum starter cable diameter mm2 79 0 54 0 79 0 54 0 79 0 54 0 79 0 54 0...

Page 63: ...th 2 pole insulation To be able to produce an isolated wiring of the generators the generators are mounted entirely insulated from the engine For this reason the generator s housings are connected to...

Page 64: ...l boxes are connected to the ship ground using ground cables Engine and gearbox mounts The engine and gearbox must be connected to the ship ground by a ground cable Remove paint from a small area to p...

Page 65: ...rnal temperatures are low and to ensure the availability of the full power output immediately after a cold start warm up phase not required For this purpose the coolant is preheated with the engine at...

Page 66: ...f the coolant is bypassed through a heat exchanger The heat generated there can be used to heat the cabins 6 5 1 2 3 4 Feed line of engine coolant to heat exchanger Return line from cabin heater Feed...

Page 67: ...ne Ball valve Union nut for threaded connection M26x1 5 To connect the pipes for the heater to be done by the shipyard threaded connections are delivered with the equipment these can be combined depen...

Page 68: ...aded as required However to ensure wire break monitoring a terminating resistor of 20 k must also be connected in parallel at the last emergency stop button 1 X4 Emergency stop 1 Emergency stop 2 2 6...

Page 69: ...terminal box MPC BB S1 S2 X13 X15 X14 MAN terminal box MPC BB S1 S2 X13 X15 X14 S1 ON S2 ON MAN terminal box MPC stdb S1 S2 X13 X15 X14 S1 ON S2 ON MAN terminal box MPC stdb S1 S2 X13 X15 X14 MAN term...

Page 70: ...levers 1 2 2 Caution To preclude confusing with other CAN bus cables please note the metal guide of the union nut and the green marking at the cable ends CAN bus connection lines and termination resi...

Page 71: ...disturbances in data communication Terminator at start of bus in engine terminal box The controller in the engine room has an internal terminating resistor dip switch S1 on the mother board which doe...

Page 72: ...stems Default setting for double engine systems S2 set to right position termination active On systems with more than two engines termination of the MPC controller in the middle must be deactivated i...

Page 73: ...iode helps suppress the voltage peaks exceeding 33 V that arise when switching off the solenoid valve LED bi directional reverse polarity protected Activation of the solenoid valves is indicated by LE...

Page 74: ...efore be marked after the engine has been installed Proceed as follows D Add the minimum amount of oil stipulated for the relevant oil pan see Operating Instructions Technical Data Then wait approx 1...

Page 75: ...side The threaded vent plugs are positioned below the coolant level in the expansion tank 1 Unscrew the threaded vent plugs 2 Fill the coolant slowly through the filler neck of the expansion tank unti...

Page 76: ...ion Overtightened caps can not be opened again 6 Switch the pump on again until coolant runs out at the threaded vent plugs without bubbles 7 Switch off the pump and tighten the threaded vent plugs 8...

Page 77: ...ontinuing engine operation this may lead to the engine monitoring system MMDS triggering the Pressure in expansion tank alarm The consequence of this alarm is a reduction in engine power There must be...

Page 78: ...Notes 76...

Page 79: ...77 Appendix...

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Page 81: ...0 M8 22 0 30 0 35 0 M8x1 23 0 35 0 40 0 M10 45 0 65 0 75 0 M10x1 25 45 0 65 0 75 0 M10x1 50 0 70 0 85 0 M12 75 0 105 0 125 0 M12x1 5 75 0 110 0 130 0 M12x1 25 80 0 115 0 135 0 M14 115 0 170 0 200 0 M1...

Page 82: ...Engine lubrication Forced feed lubrication Oil quantity in oil pan min max 50 l 60 l Oil change quantity with filter 62 l Lube oil pressure Monitored by MAN Monitoring and Diagnosis System MMDS Oil fi...

Page 83: ...300 rpm Effective mean pressure 28 5 bar Fuel consumption at full load and rated speed 225 g kWh Combustion air requirement 4100 m3 h Exhaust mass flow rate 4515 kg h Exhaust temperature at turbocharg...

Page 84: ...Engine lubrication Forced feed lubrication Oil quantity in oil pan min max 70 l 90 l Oil change quantity with filter 92 l Lube oil pressure Monitored by MAN Monitoring and Diagnosis System MMDS Oil f...

Page 85: ...300 rpm Effective mean pressure 28 5 bar Fuel consumption at full load and rated speed 215 g kWh Combustion air requirement 6300 m3 h Exhaust mass flow rate 7600 kg h Exhaust temperature at turbocharg...

Page 86: ...449 0047 15m 51 25449 0048 20m 51 25449 0058 30m 12 X9 13 Cross communication MMDS X5 51 25449 6040 2 m 51 25449 6028 5 m 51 25449 6027 10 m 14 Cross communication MPC CAN bus X13 51 25449 0056 2 m 51...

Page 87: ...MMDS CAN Bus V8 1200 V12 1800 85 1 2 3 4 5 6 10 21 23 26 7 8 1 25 22 25 9 9 9 20 19 17 16 18 15 12 13 14 11 X16 X9 X5 X15 X13 X14 X6 X8 X10 X7 X4 X1 24...

Page 88: ...optional 1st Alternator Starter motor Batteries for additional onboard consumers Terminal box Engine and gearbox brackets Starter motor Batteries for starter motor Batteries for additional onboard con...

Page 89: ...gine mounting 18 Phoenix 20 Phoenix cone 21 Engine mounts Height adjustment 29 Engine room Accessibility of the engine 13 Air ducting 24 Air requirement 23 Fans 23 Temperature 22 Ventilation 22 Engine...

Page 90: ...ng environmental damage 6 Special instructions when working on the common rail system 7 Ship ground 59 Starter motor 59 T Technical data V12 1800 82 V8 1200 80 Terminal box 62 Throttle lever control C...

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