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6. Operating instructions manual

• Page 1: Operating Instructions

  Operating Instructions MAN Marine Diesel Engines D2868 LE433 D2862 LE433/453 D2862 LE423/443/463 51.99493-8578 “Translation of the original operating instructions”…

• Page 2: Information And Copyright

  Subject to technical alterations in the interests of further development. Reprinting, copying or translating of these instructions, even in part, is forbidden without written permission from MAN. All legal copyrights remain the exclusive property of MAN. © 2011 MAN Truck & Bus AG Vogelweiherstraße 33…

• Page 3: Table Of Contents

  …………. . Engine views V8-1200 (D2868 LE433) .

• Page 4: Preface

  You can find the approved products in the internet under: https://mmrepro.mn.man.de/bstwebapp/BSTServlet 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 repair work.

• Page 5: Instructions

  Instructions Important instructions which concern technical safety and protection of persons are emphasised as shown below. Danger: This refers to working and operating procedures which must be complied with in order to rule out the risk to persons. Caution: This refers to working and operating procedures which must be complied with in order to prevent damage to or destruction of material.

• Page 6: Declaration

  Declaration…

• Page 7: Nameplates

  The engine type plates are on the crankcase (see illustration). MAN Nutzfahrzeuge Aktiengesellschaft Model Type …………..Engine No. / Engine No.

• Page 8: Safety Regulations

  D Do not touch the engine with bare hands when it is warm from operation — risk of burns. Ë Ë 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 9
  Safety regulations D Electrical accessories and equipment from other manufactures may only be connected without the approval of MAN to the connections provided for the cu­ stomer or shipyard. The control of the engine may be adversely affected and thus may lead to property damage or personal injury and is therefore not permitted.
• Page 10
  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 resulting from the install­ ation of other parts which are supposedly “just as good».
• Page 11
  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. Caution: The drinking water supply could be contaminated.
• Page 12
  Wait at least a minute until the pressure in the rail has dropped before loosening a screw connection If necessary check the pressure drop in the rail with MAN‐Cats D Risk of injury! People with pacemaker must keep at least 20 cm away from the running engine.
• Page 13
  Safety regulations D Avoid air movements (any swirling of dust when starting engines) D The area of the still closed fuel system must be cleaned and dried with the aid of com­ pressed air D Remove detached particles of dirt such as paint chippings and insulation material with a suitable extractor (industrial type vacuum cleaner) D Cover areas of the engine compartment from which dust particles could be detached with clean foil…

• Page 14: Commissioning And Operation

  Commissioning and operation Engine views V8-1200 (D2868 LE433)

• Page 15
  Commissioning and operation (1) Poly-V-belt guard (2) Air filter (3) Coolant filler neck (4) Main fuse for voltage supply (5) Oil drain valve engine (6) Oil drain valve gearbox (7) Oil filler neck (8) Oil filter (9) Oil dipstick (10) Fuel filter (11) Sea water pump (12) Engine terminal box EDC…

• Page 16: Engine Views V12-1800 (D2862 Le433) / V12-1650 (D2862 Le453)

  Commissioning and operation Engine views V12-1800 (D2862 LE433) / V12-1650 (D2862 LE453)

• Page 17
  Commissioning and operation (1) Poly-V-belt guard (2) Air filter (3) Coolant filler neck (4) Main fuse (5) Oil drain valve gearbox (6) Oil drain valve engine (7) Oil filler neck (8) Oil filter (9) Oil dipstick (10) Fuel filter (11) Sea water pump (12) IEngine terminal box EDC…

• Page 18: Engine Views V12-1550 (D2862 Le423) / V12-1400 (D2862 Le443) / D2862 Le463)

  Commissioning and operation Engine views V12-1550 (D2862 LE423) / V12-1400 (D2862 LE443) / D2862 LE463)

• Page 19
  Commissioning and operation (1) Poly-V-belt guard (2) Air filter (3) Coolant filler neck (4) Oil drain valve gearbox (5) Main fuse (6) Oil drain valve engine (7) Oil filler neck (8) Oil filter (9) Oil dipstick (10) Fuel filter (11) Sea water pump (12) IEngine terminal box EDC…

• Page 20: First Commissioning

  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-corrosion agent. See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines». D Pour in coolant slowly via expansion tank, see page 110…

• Page 21: Seawater Pump

  Commissioning and operation Seawater pump Do not let seawater pump run dry! Make sure that all valves / cocks in the seawater circuit are open. If there is a risk of frost, drain the seawater pump. Refilling with oil The engines are as a rule supplied without oil. Pour oil into engine via filler neck, see page 103.

• Page 22: Commissioning

  Commissioning and operation Commissioning Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if neces­ sary. Caution: Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc.»). Otherwise the liab­ ility for defects will become null and void! Checking oil level Check engine oil level only approx.

• Page 23: 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). There are two possibilities to start the engine: using the ignition lock or using the Start» button. Starting via the ignition lock: Ensure that the gearbox is in neutral.

• Page 24: Operation Monitoring System

  Do not put this engine into operation again until the fault has been eliminated. The engine is equipped as series standard with a monitoring and diagnostic system MAN-Marine-Dia­ gnose-System (MMDS. On the control console and alternatively on other control consoles, the following display devices are avail­…

• Page 25
  Commissioning and operation Differences in operating parameters of engines and gearboxes Differences in parameters can be observed on identical engines, irrespective if they are installed in one boat or in different boats (boat series), such as D pressures D temperatures D speeds D fuel consumption D injection quantity…

• Page 26: Engine Room Panel

  Commissioning and operation 1. Engine room panel (integrated LC display “IGN ON/OFF»-button, Start»-button, “Set+ Set-«-button and emergency stop switch) The engine room panel is optionally available and serves to display engine and gearbox data, as well as system information. In order to obtain the full functionality of an engine room panel, as well as the display additional function buttons are integrated for the control of the ignition.

• Page 27
  Commissioning and operation Function “Start» (4) (green button) With the ignition switched on, the engine can be started by pressing the green button “Start» (4). The button lights up green when the ignition is switched on. Function “Stop» (5) (yellow button) Actuation of the yellow button “IGN ON/OFF»…

• Page 28: Alarms And Flashing Lights

  Commissioning and operation Optional External LC display of the ship-vehicle management computer (SFFR) in the cover of the engine terminal box Alarms and their codings can be indicated via the external LC display of the ship-vehicle management com­ puter and communicated to our customer service organisation. If an active MMDS alarm occurs the corresponding MMDS alarm page will be indicated automatically and can be exited only after confirmation.

• Page 29
  Commissioning and operation CAN bus-controlled display devices: 2. CAN-Bus round instruments, rev counter with information display and buttons D Rev counter (0-3000 rpm) with integrated LCD display for the following parameters and buttons for pa­ ging: Engine oil pressure Gearbox oil pressure Coolant temperature Engine oil temperature Engine exhaust temperature…
• Page 30
  Commissioning and operation Tachometer CAN-Master The VDO Ocean Link Tachometer (CAN-Bus Tachometer) The VDO Ocean Link tachometer is a multifunctional instrument for indicating engine data, and is intended for use in navigation of sports ships. The tachometer shows the actual engine speed in operation, on the analogue scale.
• Page 31
  Commissioning and operation Setting possibilities Further settings can be made by pressing the button: D Selection of illumination intensity in 8 steps D Selection of display unit in metric or English units D Selection of transmitters for the analogue inputs Selection of illumination intensity If you keep the push-button pressed for 4 seconds, the scroll bar for the illumination setting appears.
• Page 32
  Commissioning and operation Setting the illumination (external illumination) Select here whether illumination of the tachometer and the connected bus instruments are to be connected internally or externally. EXTERNAL: The illumination is switched on and off through an input of the 14-pin plug. Dimming of the illumination is thus not possible.
• Page 33
  Commissioning and operation 3. MMDS-CLC 6.5 display device (colour display) Introduction This document describes how the MMDS-CMS 6.5 colour display with MMDS-CLCB 6.5 remote control op­ erates and is used in its application as an engine display to monitor engine operation. Fitting, mounting and installation are explained in separate instructions for the unit.
• Page 34
  Commissioning and operation Pre-Start page The display is activated by switching the ignition on and the following Pre-Start page is displayed. Pre-Start page If a button is actuated or the engine started, the display switches to the basic display. Pre-Start page with active acknowledged alarms Should active acknowledged alarms arise, these are indicated by a red triangle.
• Page 35
  Commissioning and operation Pre-Start page in the warning and alarm range. If a value represented on the Pre-Start page reaches the warning or alarm range, the colour of the picto­ graph changes to red. In the example shown the gearbox is not in the neutral position.
• Page 36
  Commissioning and operation Basic display On starting the engine the start page is called up automatically, indicating engine speed, coolant temperat­ ure and oil pressure in the form of round instruments and also in digital format. The calculated fuel con­ sumption is represented bottom, right.
• Page 37
  Commissioning and operation Page 3 The exhaust gas temperature values “Exhaust gas v. Turbo», and the operating hours counter are presen­ ted on page 3. Page 3 Page 4 Page 4 displays the daily fuel consumption counter “Trip». Page 4…
• Page 38
  Commissioning and operation Buttons Figure: Numbering of the operating buttons Operational functions and configuration The operation of the system and the display adjustment is carried out with the display buttons or the re­ mote control MMDS-CLCB 6.5. The following functions are incorporated: Standard function: Call the alarms table, or browse to further alarm pages.
• Page 39
  Commissioning and operation Standard function: A reset signal is sent via the CAN bus to the engine monitoring and diagnostic system control unit (engine terminal box) or to a data station. As long as the appropriate criteria are fulfilled, the engine slow down or shutdown alarms arising are reset. Additional function in the menu: Accept change and pass to the next parameter.
• Page 40
  Commissioning and operation Alarms Definition of alarm condition An alarm is triggered when a monitored value exceeds or fails to reach its set limit value. Should an alarm condition occur, an alarm table is automatically displayed. This lists all advance warnings, alarms and sensor fault alarms.
• Page 41
  Commissioning and operation Alarms table This table is automatically called when an alarm condition occurs, or can be called manually by pressing the “Alarms» button (1) It shows all existing alarm messages, i.e. those that have not been acknow­ ledged or reset. Each entry contains a measuring point text, the current measured value, the time when the alarm occurred, the unit of measurement and the type of alarm.
• Page 42
  Commissioning and operation Active alarm page Figure: Alarms table Acknowledged alarm page…
• Page 43
  Commissioning and operation Menu functions The display unit provides a number of setting options. Activation of the button (1) for approx. 3 seconds activates the menu page. The page contains the following configuration points: DSelection of the presentation in German, English, Italian, Spanish and French D Setting the time D Selection of the logo D Selection of the display in metric/non-metric units…
• Page 44
  Commissioning and operation Service page The engine and gearbox data and the alarm conditions of all measuring stations are displayed in a table on the service page. This page is accessed and exited on selecting the menu item changing the page via the buttons (2) and (3).
• Page 45
  Commissioning and operation Service page…
• Page 46
  Commissioning and operation The table has 3 columns for each measuring point. Each entry contains an abbreviation of the designation of the measuring point, the current measured value and the unit of measurement. The alarm status is presented via LED symbols. As long as the LED is green the value is in the normal range. If the initial alarm is reached the colour changes to orange and with a main alarm to red.
• Page 47
  Commissioning and operation Selection of the logo Configuration The logo to be blended in is selected on the logo page. This is displayed at the centre of all pages of the display. This page is opened or closed on selection of the menu item and changing the page via the buttons After selection of the menu item…
• Page 48
  Commissioning and operation 4. MMDS-CLC 6.5 ship’s alarm display, operation Introduction This document describes how the MMDS-CLC 6.5 colour display with MMDS-CLCB 6.5 remote control op­ erates and is used as a ship’s alarm display. Fitting, mounting and installation are explained in separate in­ structions for the unit.
• Page 49
  Commissioning and operation Standard function: page up to the next page. Additional dimming function: On simultaneous actuation of the buttons (4) and the brightness is increased. Additional function in the menu: Change parameter / increase value. Standard function: Acoustic and optical acknowledgement of all monitoring devices connected to the same CAN-Bus.
• Page 50
  Commissioning and operation a) Fuel tank: (configuration depending on boat type and tank shape) D Fill level display and digital value D with approx. 10% of the tank content, an alarm is issued (dependent on customer wish) b) Water tank: (configuration depending on boat type and tank shape) D Fill level display and digital value D with approx.
• Page 51
  Commissioning and operation k) Range: The range of the ship is displayed on the right. This is a value calculated from the current fuel consumption, GPS speed and current fuel tank content. The range can be displayed in nautical or standard miles, which can be selected in the menu. Furthermore, the fuel consumption and e.g.
• Page 52
  Commissioning and operation Alarms table This table is automatically called when an alarm condition occurs, or can be called manually by pressing the button (1) It shows all existing alarm messages, i.e. those that have not been acknowledged or reset. Each entry contains a measuring point text, the current measured value, the time when the alarm oc­ curred, the unit of measurement and the type of alarm.
• Page 53
  Commissioning and operation Menu functions The display unit provides a number of setting options. Activation of the button (1) for approx. 3 seconds activates the menu page. The page contains the following configuration points: D Setting the time D Selection of the presentation in German, English, Italian, Spanish and French D Selection of the display in metric/non-metric units D Activation of the service page The menu point in the respective red marked field can be changed with the buttons…
• Page 54
  Commissioning and operation Selection of the logo Configuration The logo to be blended in is selected on the logo page. This is displayed at the centre of all pages of the display. This page is opened or closed on selection of the menu item and changing the page via the buttons After selection of the menu item…
• Page 55
  Clear and user-friendly displays are a precondition for safe operation of any ship. The MAN Monitoring System represents a new component of the proven alarm, safety and diagnostic sys­ tem MMDS, which offers a variety of new functions and display formats. The PC-based system is used to display operating data of several engines and general ship messages.
• Page 56
  Commissioning and operation Function and operation Display functions The display is switched on and off using the Power button (top right). Underneath this, there are four sys­ tem keys for adjustment of the display illumination and for maintenance of the display. Usually, only the ar­ row keys are important.

• Page 57: Software Description

  The amount of information is steadily increasing and must be registered and evaluated quickly. The MAN Monitoring System MMDS-CMS belongs to the Alarm, Safety and Diagnostic Unit MMDS. It offers a variety of functions and types of display, which are mainly defined by the visualisation software.

• Page 58
  Commissioning and operation Scope of services The monitoring system registers, evaluates and displays engine and gearbox data of MAN ship’s diesel en­ gines. The measured values are registered via the MMDS diagnostic units, one of which is placed each of the engine terminal boxes.
• Page 59
  Commissioning and operation Operation The displays are activated automatically when the power supply is switched on. They can be switched on and off individually by pressing “Power» button Ê. The computers can be switched on and off when the power supply is switched on. The startup procedure of the operating system Windows XP, as well as of the visualisation software, takes approx.
• Page 60
  Commissioning and operation Function: opens a page which shows visual representations of the engines with the corresponding measured values (see page 69, Visual engine display). Function: opens the alarm screen. Here, the acknowledged and unacknowledged alarms are displayed in tabular form (see page 73, Tabular display of alarms). Function: opens the measuring point lists.
• Page 61
  Commissioning and operation Function: (only available in the measuring point list or in the alarm table): shows / hi­ des legend with explanations for the table column “Kind of alarm». Function: opens the instrument selection menu. An instrument selected here is dele­ ted, if present.
• Page 62
  Commissioning and operation Main menu (start page) After switching on the system, the start page is shown first of all. The start page can be called up via the “MAIN MENU» function from any other page. The most important measured values of both engines are summarised here and displayed in large digits.
• Page 63
  Commissioning and operation Settings page (Adjustments) The time and units (metric or imperial system) are set on the settings page. The display of the mouse pointer, as well as the commissioning sensors, can be enabled and disabled here. This page is only accessible from the “Main Menu» page. Pushing the F7 key opens the settings page. Values are set using the F5 and F6 function keys.
• Page 64
  Commissioning and operation Analogue display This page is opened using the “ANALOGUE» function. The most important engine and gearbox data is visualised as instrument dials in this display. The battery voltage and current fuel consumption are shown digitally. The unacknowledged alarms, as well as the date and time, can be found in the lower section. Description of function Area for depiction of port en­…
• Page 65
  Commissioning and operation Digital display This page is opened using the “DIGITAL» function. Important engine and gearbox data is shown here as bar displays. This form of representation enables easy evaluation of the registered data, including how far they are away from limit values, as well as their relationship to other values. Battery voltage, current fuel consumption and total operating hours for both engines are displayed digitally.
• Page 66
  Commissioning and operation User-defined display The user can configure the instrument range as desired in the user-defined display. All instruments can be defined as regards their size and type of representation. Important measuring points can thereby be high­ lighted visually. The instruments are available in different forms of display. For example, exhaust gas tem­ peratures can be represented as thermometers or instrument dials;…
• Page 67
  Commissioning and operation Configuration of user-defined display A mouse or trackball and a keyboard must be connected to the MMDS-CMS S compact PC in order to con­ figure this display. To insert or delete an instrument, click on the softkeys to open the selection menu on the softkeys (the F7 and F8 keys are disabled here, as a mouse or another pointer devices is required).
• Page 68
  Commissioning and operation To shift an instrument, click to select it and drag with the mouse button pressed (drag and drop). Figure: shifting an instrument The following configuration window appears on clicking an instrument while holding down the [Shift] key. The size of an instrument can be adjusted here between 250 and 400 pixels.
• Page 69
  Commissioning and operation Visual engine display In the graphical display, the exhaust gas temperatures are shown at the relevant installation positions of the sensors. Other measuring points and binary alarms are located in the lower half of the page shown. The instrument area is divided into two halves.
• Page 70
  Commissioning and operation Display of all measuring points List of measuring points This display shows tables of all the measuring points available in the system. The “ENGINE PORT» and “ENGINE STBD» keys are used to select the list for the respective engine. This view can be opened from all other pages by pressing the “MEASURING POINTS»…
• Page 71
  Commissioning and operation Structure of the table The columns “Measuring point“, “Unit», “Value» and “Kind of Alarm» in the tabular display mean: Measuring point Contains the designation of the measuring point Unit Contains the unit of the measurement variable Value Contains the current measured value Min / Max Identification of the type of monitoring of the limit value…
• Page 72
  Commissioning and operation Alarm and limit value display Dynamic limit value display Limit values depending on the speed are represented dynamically by the monitoring system. In the follow­ ing illustration, the speed was changed at constant oil pressure. The rise in the limit value can be recog­ nised with increasing speed.
• Page 73
  Commissioning and operation Tabular alarm display There is a graphical alarm display in parallel to a tabular display. There is an “Alarms» table in the display that contains all alarms and the “Unacknowledged alarms» table with all unacknowledged alarms. Both can be seen in the alarm table.
• Page 74
  Commissioning and operation Alarm table and alarm acknowledgement Each new alarm flashes initially in the top line. Existing alarms move down one line. On acknowledgement, the flashing display of all alarms turns into constant light. If there are more alarms than can be represented, the user can use the “ALARM TABLE UP»…
• Page 75
  (the engine must stop immediately when the button is pressed once). At the request of the shipyard or customer, it is possible to purchase from MAN an electronic drive lever control system made by Bosch-Rexroth, model Marine Power Control.
• Page 76
  Commissioning and operation The control head is used to control engine speed and the gearbox. The operation takes place via the control lever and four buttons. On twin engine installations the left control lever operates the port engine and gearbox and the right lever the starboard engine and gearbox.
• Page 77
  Commissioning and operation “Gearbox forwards / reverse» (lock) position (2) In this lever position, two different functions are possible. 1. Standard function: The gearbox clutch is engaged to Forwards» or Reverse»; the power unit is idling. 2. “Increase engine speed» function The Increase engine speed»…
• Page 78
  Commissioning and operation Description of buttons Button Function Request command “Activate control console», see page 79 Accept command “Change control console», see page 80 Engine warm up “Engine Warm Up», see page 81 Acknowledge alarm “Acknowledge alarm», see page 86 Adjust brightness of LEDs “Adjust brightness»…
• Page 79
  Commissioning and operation Description of acoustic signal transmitter Warnings and alarms can be reproduced via the acoustic signal transmitter.. Interval signal Event Meaning tone fast actuation of the button Handover of the control console possible Initialisation of the connected control Handover of the control console is requested slow actuation of the button…
• Page 80
  Commissioning and operation Change control console Note: The control console can only be changed, when no directional change is taking place in the gear­ box. Current control console Control console to accept control «Ahead range» “Ahead» range or “Neutral» “Neutral» range Neutral Astern range “Astern»…
• Page 81
  Commissioning and operation Engine Warm Up Caution: Do not exceed the permissible highest engine speed. Note: On vessels with twin engine drive the port and starboard engines can be warmed up independ­ ently. Start the “Warm Up» function 1. Set the respective control head in the “Neutral“ detent. 2.
• Page 82
  Commissioning and operation Control engines at the same engine speed 1. Set both levers in the range between “Ahead» and “Full ahead» (max. deviation of the levers from each other 10%). 2. Press button. Both engines are regulated to the same engine speed. The LEDs light.
• Page 83
  Commissioning and operation Switch offsynchronisation Danger: On switching off the synchronisation, the speeds of both engines revert to the speeds set by the respective levers. The direction of travel of the vessel changes if the lever settings are not identical. Press button.
• Page 84
  Commissioning and operation Switchtrolling on and off Control of the propellor slip of a trolling transmission can be specified with the “Trolling» function. Thus the propulsion of the vessel can be reduced when manoeuvring. Prerequisite: The vessel must be equipped with a trolling transmission. Danger: On activating the trolling function a reduction in engine speed may result.
• Page 85
  Commissioning and operation Switch SLIP & GRIP on and off Prerequisite: The vessel must be equipped with a trolling transmission. The transmission function “SLIP & GRIP“ is a combination of trolling in the lower lever range and normal operation in the upper lever range. This enables a more precise control of vessel speed at slower speeds. However, maximum speed can be selected at any time.
• Page 86
  Commissioning and operation Continuously adjust display brightness Hold button pressed and wait until the brightness of the display changes. When the display becomes brighter, you can adjust the display brightness up to maximum bright­ ness. When the display becomes darker, the brightness first reaches the minimum brightness and then be­ comes brighter again.
• Page 87
  Commissioning and operation The following alarm messages can occur: Message Meaning Warning Remote control fault, which does not have a direct effect on the con­ Alarm lamp without signal tone trollability of the drive system, e.g. control head of another control con­ sole damaged.
• Page 88
  Anchor winch bow thruster Down button Starboard button bow thruster stern thruster Port Starboard button stern thruster starboard alarm LED Port portside alarm LED trolling LED portside command LED trolling push-button starboard command LED dead man’s switch command push-button Buzzer…
• Page 89
  Commissioning and operation Description of the operating elements: General: After switching on the supply voltage for the Mini-Marex system and the entire system of the mobile navig­ ating console, all correctly functioning command masters are in the state ‘lamp test’ (all LEDs and buzzers on).
• Page 90
  Commissioning and operation Trolling push-button: button can only be pressed in neutral position of the command master levers. The function is ac­ tivated by pressing the button and is indicated by the Trolling LED lighting up. Pressing the button again (the command master levers must also be in neutral position) switches off the trolling function..
• Page 91
  Dead man’s switch: The supporting loop of the dead man’s switch at the hand-held remote control is to be looped around the user’s wrist during operation of the hand-held remote control. In case of loss of the hand-held remote con­…
• Page 92
  Commissioning and operation 7. Emergency operation unit:: The emergency operation control system — Em — is conceived as a simple engine speed and gearbox control system which enables safe continuation of a trip in the event of a failure in the electrical con­ trol lever system.
• Page 93
  Commissioning and operation Operating the emergency operation unit Requirements for operation / activation / deactivation: D The emergency running control system should be only activated while the engine is running. Otherwise the “System Failure» LED flashes to indicate there is no engine speed signal D The engine should be shut down via the ignition lock When the emergency stop button is pressed, the “System Failure»…
• Page 94
  Commissioning and operation Gearbox control When emergency running mode is active, the gearbox is engaged in the neutral, forwards or astern posi­ tions by means of 3 button functions: Shift gearbox to neutral position Shift gearbox to forwards position Shift gearbox to reverse position Gearbox reversal will only take place when the engine speed is in the idle range.
• Page 95
  Commissioning and operation Deactivating emergency running mode Emergency running mode is always deactivated only after the engine has been shut down, it is necessary for the ignition to have been turned off for at least 3 seconds. When the ignition is turned on again, normal throttle lever mode is always activated first, i.e. the emergency running system must be reactivated as required.
• Page 96
  (off position). Urgent recommendation: Determine the cause of the drop in power output (alarm)! If pressing the Override button leads to engine damage, this is not covered within the framework of MAN’ li­ ability for defects. Override button…
• Page 97
  Commissioning and operation Main fuses for voltage supply + / — to the en­ gine Two main fuses with 50 A are fitted at the engine; these trip in the event of overcurrent or short cir­ cuit. If a fuse as blown, the engine can no longer be started.

• Page 98: Shutting Down

  Commissioning and operation Shutting down Do not switch off engine immediately operation at high loads, but let it idle for about 5 minutes to achieve a temperature equalisation. Set the deck switch to “Neutral» and switch off the engine by means of the ignition key or Ignition button. Remove key from starting lock.

• Page 99: Maintenance And Care

  Maintenance and care Lubrication system Ensure utmost cleanliness when handling fuels, lubricants and coolants. Caution: Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc.»). Otherwise the liab­ ility for defects will become null and void! Refilling with oil Danger: The oil is hot-risk of scalding.

• Page 100
  Maintenance and care Unscrew the oil filter cover (1) and remove it, to­ gether with the oil filter insert (3). Remove the oil filter insert (3) from the oil filter cover. Remove the sealing ring (2) from the oil fil­ ter cover.
• Page 101
  Maintenance and care Electric oil drain pump (option) for engine and gearbox oil Pump off engine oil Unscrew the sealing cap of the oil drainage hose (1). Connect the suction line (2) of the oil drainage pump to the engine oil drainage hose (1). With the installation hot after running, press the “OIL OUT»…
• Page 102
  Maintenance and care Pump off gearbox oil Unscrew the sealing cap of the oil drainage hose (1). Connect the suction line (2) of the oil drainage pump to the oil drainage hose (1) of the gearbox. With the installation hot after running, press the “OIL OUT»…
• Page 103
  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 (arrow).

• Page 104: Fuel System

  Maintenance and care Fuel system Fuel If diesel fuel containing water is used, damage is caused to the injection system. To some extent this can be avoided by filling up with fuel after stopping the engine, while the fuel tank is still warm (prevention of condensation of water).

• Page 105
  Unscrew drain plugs at every oil change until mois­ ture has been discharged and clean fuel flows out Caution: Danger of dirt ingressing the fuel system! The fuel filter must only be replaced by an appointed MAN customer service centre.
• Page 106
  Maintenance and care Fuel pre-filter with water separator The fuel pre-filter with water separator is built into the fuel feed line between the tank and the engine. Caution: Pay attention to the position of the 3-way cock handle. Handle in position: A Continuous operation (both filter halves in operation) B Left side switched off…
• Page 107
  Maintenance and care Bleeding the fuel system Danger: Only bleed the fuel system with the en­ gine switched off. Note: To bleed the fuel system switch on the “ignition». D Loosen threaded vent plugs (1) D Loosen the hand pump plunger D Actuate the hand pump plunger until the fuel is bubble-free at the threaded vent plugs (1) outlet D Tighten the threaded vent plugs (1) to 25 Nm…

• Page 108: Cooling System

  Maintenance and care Cooling system Danger: Draining hot coolant involves a risk of scalding. Draining the cooling system Danger: Only empty the cooling system with the engine switched off. Caution: Drain coolant into a suitable container and dispose of it in accordance with regu­ lations.

• Page 109
  Maintenance and care D Unscrew the plug (5) on the exhaust manifold on the left side of the engine and drain the coolant.(6) D Screw the plug on again (5) and tighten D Filling / bleeding the cooling system…
• Page 110
  Maintenance and care Fill / bleed the cooling system (only when engine has cooled down) Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze agent on an ethyl­ ene glycole basis or anti-corrosion agent. Caution: Use only approved fuels, lubricants etc.
• Page 111
  Maintenance and care D Stop the engine D Check the coolant at the sight glass (1) of the expansion tank, which must be between “min» and “max» D When topping up, carefully loosen the locking cap (2) with safety valve -release the pressure- then carefully open and fill up with coolant.
• Page 112
  Maintenance and care If it is necessary to fill the expansion tank when the engine is hot, the following should be noted: D In order to be able to operate the hot engine again without an alarm, after opening the lock­ ing cap, there must be an admission pressure of 0.7 bar in the cooling system.
• Page 113
  Maintenance and care Change air filter Danger: Only replace the air filter with the engine switched off Remove air filter Loosen the hose clamp (2) and remove the air fil­ ter (1) from the intake neck (3). Removal of the second air filter takes place by analogy.
• Page 114
  Maintenance and care V-ribbed belt Danger: Inspect/replace the V-ribbed belt only with the engine stopped. Checking condition D Check V-ribbed belt for cracks, tears, oil foul­ ing, signs of overheating and wear D Replace damaged V-ribbed belt Replace V-ribbed belt Caution: Danger of crushing! The V-ribbed belt tensioner is under…

• Page 115: Alternator

  D Do not operate the alternator without battery connection! Temporary decommissioning of engines Temporary anti-corrosion protection according to MAN works standard M 3069 is required for engines which are to be put out of service for fairly long periods. The works standard can be obtained from our After-Sales Service department Nuremberg works.

• Page 116: Technical Data

  Technical data Model V8-1200 (D2868 LE433) Design V 90° Cycle 4-stroke diesel Combustion system Direct injection Turbocharging 2-stage exhaust turbocharger with intercooler and charge-air regulation (Waste Gate) Number of cylinders Bore 128 mm Stroke 157 mm Swept volume 16 160 cm…

• Page 117
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 50 l 60 l Oil change quantity (with filter) 62 l Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling system Liquid cooling Coolant temperature 80-90°C, temporarily 95°C allowed…
• Page 118
  Technical data Model V12-1800 (D2862 LE433) Design V 90° Cycle 4-stroke diesel Combustion system Direct injection Turbocharging 2-stage exhaust turbocharger with intercooler and charge-air regulation (Waste Gate) Number of cylinders Bore 128 mm Stroke 157 mm Swept volume 24 243 cm Compression ratio 17:1 Rating…
• Page 119
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 70 l 90 l Oil change quantity (with filter) 92 l Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling system Liquid cooling Coolant temperature 80-90°C, temporarily 95°C allowed…
• Page 120
  Technical data Model V12-1650 (D2862 LE453) Design V 90° Cycle 4-stroke diesel Combustion system Direct injection Turbocharging 2-stage exhaust turbocharger with intercooler and charge-air regulation (Waste Gate) Number of cylinders Bore 128 mm Stroke 157 mm Swept volume 24 243 cm Compression ratio 17:1 Rating…
• Page 121
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 70 l 90 l Oil change quantity (with filter) 92 l Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling system Liquid cooling Coolant temperature 80-90°C, temporarily 95°C allowed…
• Page 122
  Technical data Model V12-1550 (D2862 LE423) Design V 90° Cycle 4-stroke diesel Combustion system Direct injection Turbocharging Exhaust turbocharger with intercooler and charge- air regulation (Waste Gate) Number of cylinders Bore 128 mm Stroke 157 mm Swept volume 24 243 cm Compression ratio 17:1 Rating…
• Page 123
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 70 l 90 l Oil change quantity (with filter) 92 l Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling system Liquid cooling Coolant temperature 80-90°C, temporarily 95°C allowed…
• Page 124
  Technical data Model V12-1400 (D2862 LE443) Design V 90° Cycle 4-stroke diesel Combustion system Direct injection Turbocharging Exhaust turbocharger with intercooler and charge- air regulation (Waste Gate) Number of cylinders Bore 128 mm Stroke 157 mm Swept volume 24 243 cm Compression ratio 17:1 Rating…
• Page 125
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 70 l 90 l Oil change quantity (with filter) 92 l Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling system Liquid cooling Coolant temperature 80-90°C, temporarily 95°C allowed…
• Page 126
  Technical data Model D2862 LE463 Design V 90° Cycle 4-stroke diesel Combustion system Direct injection Turbocharging Exhaust turbocharger with intercooler and charge- air regulation (Waste Gate) Number of cylinders Bore 128 mm Stroke 157 mm Swept volume 24 243 cm Compression ratio 17:1 Rating…
• Page 127
  Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. 70 l 90 l Oil change quantity (with filter) 92 l Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling system Liquid cooling Coolant temperature 80-90°C, temporarily 95°C allowed…

• Page 128: 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 129
  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 130: Index

  Index Alternator ……. Operation monitoring CAN-Bus round instruments, rev counter with information display and buttons .

• Page 132
  MAN Truck & Bus AG Vogelweiherstraße 33 90441 Nürnberg Germany A member of the MAN Group Printed in Germany 51.99493-8578…

GENERAL

The inline engines of the D 2876 LF series underwent major modification for the heavy-duty MAN Trucknology Generation (TGA):

Example TGA 26o530

Example:

BASICS OF TORQUE

A TORQUE C SPECIFIC FUEL CONSUMPTION

Power and torque increase with speed. After overcoming the friction loss and greater heat losses at low speeds, the engine achieves its maximum torque with optimum filling of the cylinder. If speed increases further, the torque drops because of the greater flow resistance and short valve opening times.

The full-load consumption curve in the diagram can be explained by the fact that you get less than good fuel consumption in the low range of speed because of the poor pressure mix of the fuel particles (14.5:1). At high speeds, combustion is imperfect because of the short time that is available. And fuel consumption increases.

B POWER

Power is the product of speed and torque. Seeing as the drop in torque is slower than the increase in speed, there is initially an increase if the power output of an engine. Between the maximum torque and the maximum power there is an elastic range in which power is kept constant by increasing torque although the speed is dropping.

Setting of timing

The marking of the crank shaft gear must match with the marking of the shrink-fit cam shaft gear (not the same as TDC of cylinder 1).

4Cam shaft

5Intermediate gear for high pressure pump

6High pressure pump drive

7Auxiliary drive

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