Man D2868 LE433 Operating Instructions Manual Download Page 1

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Operating Instructions

MAN Marine Diesel Engines

D2868 LE433
D2862 LE433/453
D2862 LE423/443/463

51.99493-8578

“Translation of the original operating instructions”

Summary of Contents for D2868 LE433

Page 1: ...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: ...ons even in part is forbidden without written permission from MAN All legal copyrights remain the exclusive property of MAN 2011 MAN Truck Bus AG Vogelweiherstra e 33 90441 N rnberg Germany Tel 49 911...

Page 3: ...V12 1800 D2862 LE433 V12 1650 D2862 LE453 16 Engine views V12 1550 D2862 LE423 V12 1400 D2862 LE443 D2862 LE463 18 First commissioning 20 Commissioning 22 Starting 23 Operation monitoring system 24 S...

Page 4: ...te of the art However trouble free operation and high performance can only be achieved if the specified maintenance intervals are observed and only approved fuels lubricants and coolants are used Note...

Page 5: ...s 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...

Page 6: ...Declaration 6...

Page 7: ...aces The engine type plates are on the crankcase see illustration Model delivered on installed on Engine serial number Order number MAN Nutzfahrzeuge Aktiengesellschaft Type Engine No Engine No NI II...

Page 8: ...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 9: ...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 close to ro tating parts D Change the oil when the engines...

Page 10: ...components of diesel injection consist of high precision parts which are exposed to ex treme stresses The high precision technology requires the utmost cleanliness during all work on the fuel system E...

Page 11: ...basic 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 con...

Page 12: ...ep at least 20 cm away from the running engine Do not touch live parts on the electric connection of the injectors when the engine is running Cleanliness Today modern components of diesel injection co...

Page 13: ...s and working materials before starting to work D Only tools without any damage may be used cracked chrome coatings D When removing and installing components do not use materials such as cloths cardbo...

Page 14: ...Commissioning and operation 14 Engine views V8 1200 D2868 LE433 2 3 4 5 6 7 8 9 1 10 11 10 12 3 8...

Page 15: ...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 w...

Page 16: ...Commissioning and operation 16 Engine views V12 1800 D2862 LE433 V12 1650 D2862 LE453 2 1 9 8 7 6 5 4 3 3 8 12 10 11 10...

Page 17: ...17 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...

Page 18: ...Commissioning and operation 18 Engine views V12 1550 D2862 LE423 V12 1400 D2862 LE443 D2862 LE463 1 2 3 4 5 6 7 8 9 3 8 12 10 11...

Page 19: ...19 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...

Page 20: ...ually Caution Use only approved fuels lubricants etc see brochure Fuels lubricants etc Otherwise the liab ility for defects will become null and void Filling with fuel Caution Fill the tank only when...

Page 21: ...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 Caution Do not add so much engine oil that the...

Page 22: ...oil level only approx 20 minutes after the unit has been switched off DPull out dipstick arrow D wipe it with a clean lint free cloth D and push it in again up to the stop D Pull out dipstick again Th...

Page 23: ...t 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...

Page 24: ...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 c...

Page 25: ...ifferences may be caused by D component tolerances of the mechanical and electrical engine components D design related influences on engines this applies especially to the exhaust temp D external infl...

Page 26: ...ion starting the engine and for engine speed adjustment 5 4 3 2 1 1 Set 2 Set 3 Emergency stop 4 Start 5 ING Ignition Function Ignition ON OFF 5 yellow button After activated ignition at the control c...

Page 27: ...gnition must be switched off and on again in order to restart the engine Engine speed adjustment Function Set 1 By actuating the button Set 1 with the engine running the engine speed is increased Func...

Page 28: ...shing light Indication of EDC SFFR fault with high priority Permanent light Indication of EDC SFFR fault with low priority Flashing light Active non confirmed MMDS alarm Permanent light Active confirm...

Page 29: ...d buttons for pa ging Engine oil pressure Gearbox oil pressure Coolant temperature Engine oil temperature Engine exhaust temperature Charge air temperature Boost pressure Load Hours of operation Fuel...

Page 30: ...ns can be selected Handling of the instrument is thus easy and uncomplicated Main Functions The main functions of the VDO Ocean Link can be called up by pressing the push button Each time the button i...

Page 31: ...n the settings menu see page 32 Basic Settings The basic settings necessary for perfect operation can be selected in the settings These are obtained by pressing and holding the button while switching...

Page 32: ...alue is displayed NO No change in the setting are made Activation of the simulation mode simulator mode Select here whether the simulation mode is to be switched on YES The simulation mode is switched...

Page 33: ...plemented by a table which lists all alarms present with more detailed information A logo which will be displayed on all pages may be activated when installed The shipyard can select this logo selecti...

Page 34: ...re 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 acknowled...

Page 35: ...e 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 gearbo...

Page 36: ...oolant 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 Basic display Engine and gearbox data are...

Page 37: ...and operation 37 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 counte...

Page 38: ...and 3 the brightness is reduced Additional function in the menu Change parameter reduce value Standard function page up to the next page Additional dimming function On simultaneous actuation of the bu...

Page 39: ...ong 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 Function Actuation...

Page 40: ...On reaching a prelim inary alarm the digital value flashes orange with a main alarm red and in the case of a sensor fault a yel low flashing SE appears On pressing the optical acknowledgement Button 4...

Page 41: ...highlighted in flashing red until it is visually acknow ledged Older messages are automatically displaced one line downwards If there are more than 6 entries further alarm pages are automatically pres...

Page 42: ...Commissioning and operation 42 Active alarm page Figure Alarms table Acknowledged alarm page...

Page 43: ...Setting the time D Selection of the logo D Selection of the display in metric non metric units D Activation of display start status D Activation of the service page The menu point in the respective b...

Page 44: ...e 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 and chang...

Page 45: ...fil Service page 2 2 Exhaust temp 1 Exhaust temp 2 Exh temp aft turbo EDC failure SFFR failure Remote slow down Override Emergency stop Alarm throttle cont Safety syst fail Alarm safety syst Engine n...

Page 46: ...ng LED indicates that the alarm has not yet been visually acknowledged If there is a sensor failure the LED goes out Automatic dimming A photo element is integrated in the front plate of the display u...

Page 47: ...and After selection of the menu item by actuating the button an available logo can be selected via the buttons and After activation of the button for approx 3 seconds the selection is accepted and th...

Page 48: ...states of all sensors can be viewed at a glance To optimise adjustment to the user s requirements five languages and display of the data in either metric or non metric units can be selected Buttons 6...

Page 49: ...it 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 an...

Page 50: ...re gard to configuration tank curves and possible signal inputs Page 2 Normally the following is displayed Figure page 2 with digital display elements and bar displays g Trim flap position here is an...

Page 51: ...advance warnings alarms and sensor fault alarms An internal buzzer and the horn relay are activated at the same time The collective alarm relay issues a repeat pulse if another alarm was already activ...

Page 52: ...new alarm always appears in the top line This is highlighted in flashing red until it is visually acknow ledged Older messages are automatically displaced one line downwards If there are more than 10...

Page 53: ...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 2 and 3 Pressing the button 5 switches the...

Page 54: ...buttons and After selection of the menu item by actuating the button an available logo can be selected via the buttons and After activation of the button for approx 3 seconds the selection is accepte...

Page 55: ...f new functions and display formats The PC based system is used to display operating data of several engines and general ship messages The 10 15 MMDS CMS 10 15 TFT monitor is part of the system Data t...

Page 56: ...r values Software operation The MMDS CMS 10 15 monitor serves to display and control visualisation software that is installed on the PC This software is adapted to the overall system and is explained...

Page 57: ...ly configured by the user In addition the engines are represented graphically In the event of a fault the source of the problem can be recognised easily A further special feature is the dynamic displa...

Page 58: ...Ten function keys are integrated in each of the monitors This enables functions such as page selection or scrolling On connection of mouse and keyboard one of the pages can be freely configured On the...

Page 59: ...currently possible functions are explained in a specifically assigned section of the display located to the right of each key Insofar as a field is empty the assigned key does not have any function M...

Page 60: ...shown Function only available on settings page selects the next adjustable element Function only available on settings page selects the previous adjustable element Function only available on settings...

Page 61: ...ar display appears which indicates the current brightness in It is controlled by holding down the keys The brightness is re duced using the key and increased using the key Acknowledgement The keys on...

Page 62: ...t important measured values of both engines are summarised here and displayed in large digits The unacknowledged alarms as well as the date and time can be found in the lower section Description of fu...

Page 63: ...value by one pushing the F6 key reduces the value accordingly The appropriate key can also be held down to accelerate setting of the time The value to be set next is activated with the NEXT ELEMENT F2...

Page 64: ...play 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 Table of all unacknowledged alarms Ar...

Page 65: ...alues Battery voltage current fuel consumption and total operating hours for both engines are displayed digitally In a similar way to the other graphical pages the table with the unacknowledged alarms...

Page 66: ...struments are available in different forms of display For example exhaust gas tem peratures can be represented as thermometers or instrument dials the speed can be shown as an instru ment dial or mete...

Page 67: ...lick 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 Various instruments are available in this menu fo...

Page 68: ...ppears on clicking an instrument while holding down the Shift key The size of an instrument can be adjusted here between 250 and 400 pixels To do this the orange indic ator on the scale is dragged wit...

Page 69: ...arms are located in the lower half of the page shown The instrument area is divided into two halves The measuring points for the starboard are arranged in the right half those for the port are shown i...

Page 70: ...tive engine This view can be opened from all other pages by pressing the MEASURING POINTS key The complete list can be viewed by pressing the TABLE UP or TABLE DOWN keys Selection of the BACK key open...

Page 71: ...f alarm monitoring The following identifiers are distinguished at Min Max D NORM Normal state D XAExternal alarm D FAULT Failure alarm D TIAH Temperature limit value exceeded D TIAL Temperature limit...

Page 72: ...ached the corresponding instrument starts flashing In the event of an alarm the instrument flashes until the alarm state is acknowledged Two keys to the right of the display are used for the acknowled...

Page 73: ...ructure of the table The columns Measuring point Unit Value Time Date and Kind of alarm in the tabular display mean Measuring point Contains the designation of the measuring point Value Contains the m...

Page 74: ...re acknowledged on operation Function Visual acknowledgement which means that all flashing alarms switch to conti nuous light if they have previously been acknowledged acoustically All monitoring devi...

Page 75: ...tion due to damaged control head Humidity may ingress into the damaged control head The vessel can then no longer be controlled correctly Inspect the control head for visible damage before every opera...

Page 76: ...stallations the handle on the control lever is the universal control Function Max speed Max speed Infinitely variable speed adjustment Infinitely variable speed adjustment lock Ahead range Gearbox ahe...

Page 77: ...t is lowered again to idling speed Between the clutch engaging operations individual delays waiting periods BEFORE and AFTER clutch engaging can be set Maximum engine speed position 3 Position 3 shows...

Page 78: ...Slip Grip ope rating function Switch Slip Grip on and off see page 85 Switch on and off the Trolling opera ting function Switch Trolling on and off see page 84 Description of LEDs LED Function Separa...

Page 79: ...ter switch first all control consoles are initialised This is indicated by a slow flashing LED on each control console D D and an unbroken acoustic signal During the initialisation D the control conso...

Page 80: ...ct the control head by actuating the button If the levers are not in the Neutral position the LEDs flash slowly and the signal tone is likewise slow Adjust the lever of the control head according to t...

Page 81: ...e speed corresponds to the lever setting the gearbox remains disengaged Exit the Warm Up function The Warm Up function is stopped by moving the lever to Neutral Synchronise engine speeds On twin engin...

Page 82: ...e master system forward The LED of the master system remains lit the LED of the slave system goes out Note If the speed of the slave system is increased the SYNCHRO function reverts to the Stand by mo...

Page 83: ...f 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 The synchronisation is deactivated N...

Page 84: ...ole to the Neutral detent The gearboxes are now disengaged 2 Press button The LEDs light The TROLLING transmission function is activated Navigate with trolling When the lever is at the Ahead or Astern...

Page 85: ...peed can be selected at any time Danger On switching off the SLIP GRIP the vessel can undergo moderate accelerations Switch on Slip Grip 1 Set the lever on the active control console in the Neutral de...

Page 86: ...o continuously adjust the display brightness Release button briefly and then press again The dimming direction reverses Acknowledge alarm Alarm messages are optically displayed to all control consoles...

Page 87: ...e ve ssel Surface visibly damaged water has penetrated the unit Replace device The WARM UP function will not start Lever does not remain in the Neutral detent Warm Up chapter see page 81 The TROLLING...

Page 88: ...n full astern Neutral full ahead astern ahead 1 Detent 1 Detent astern ahead As an additional user interface the following operating elements are provided Anchor winch Anchor winch Down button bow thr...

Page 89: ...d by pressing the push button once again D The two LEDs flash and the buzzer beeps slowly when no command takeover is possible An error cause can be that the command master levers are not located in t...

Page 90: ...hes off the trolling function Synchronising The command can also be adopted by the mobile navigating console when the active navigating console is in the synchronisation mode Here the synchronisation...

Page 91: ...d held remote control has command again passiveop erating mode When requesting command without a dead man s switch being provided the following error messages will occur 1 Both alarm LEDs will be ligh...

Page 92: ...le When the ignition is on emergency running can be activated by way of appropriate function buttons A green LED indicates operational readiness Operation is effected by way of six front buttons which...

Page 93: ...ration Enabling emergency operation unit The system is ready for operation once the ignition has been turned on This is indicated by the green Power On The red LED Failure must not light up The emerge...

Page 94: ...to each active reversal opera tion The relevant pressed button flashes until the desired status is reached It goes out when another control command is given or lights up permanently to indicate that...

Page 95: ...es without another operator button also flashing Drop out of internal speed signal function with delayed reversal times nevertheless still possible Green LED on red LED flashes together with forwards...

Page 96: ...Function If the engine output has been reduced due to an alarm there is the possibility to press the Override button once LED on and recover the original power output of the engine If there is anothe...

Page 97: ...short cir cuit If a fuse as blown the engine can no longer be started The fuses can be reset by the operator using the keys fitted Main fuse on the control unit carrier EDC A further 3 main fuses arr...

Page 98: ...t 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 k...

Page 99: ...ndle it with care With the engine at operating temperature remove the oil drain plug on the oil sump and the oil filter bowl and allow the old oil to drain off completely Use a vessel of sufficient si...

Page 100: ...from the oil filter cover Remove the sealing ring 2 from the oil fil ter cover Fit new sealing ring 2 to the filter cover 1 Insert the new oil filter insert 3 into the oil filter cover 1 Insert the oi...

Page 101: ...nto a container of adequate capacity Note Change the oil filter elements every time the engine oil is changed Fill the engine with engine oil Fill the engine with engine oil via the discharge hose 1 b...

Page 102: ...container of adequate capacity Fill the gearbox with gear oil Fill the gearbox with gearbox oil via the discharge hose 3 by pressing the OIL IN button Caution Do not add so much gearbox oil that the...

Page 103: ...essure builds up after approx 10 seconds switch off the engine immedi ately Check oil pressure and check that there is no oil leakage Then shut down the engine After about 20 minutes check the oil lev...

Page 104: ...uthor ised to perform such work Cleaning fuel pre cleaner Danger Only service the fuel prefilter with the en gine switched off Close shut off valves between engine and tank Strip the fuel pre cleaner...

Page 105: ...g moisture 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...

Page 106: ...drain water off into a container of adequate capacity D Close drain screw 1 D Water draining of the 2nd filter cartridge is car ried out by analogy Replace fuel filter cartridge D Turn handle to posit...

Page 107: ...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 ou...

Page 108: ...cooling system has cooled down D Briefly open the locking cap 1 on the filler neck of the expansion tank to equalise the pressure D Unscrew the locking cap 4 of the coolant drain valve 2 and open the...

Page 109: ...tenance and care 109 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 5...

Page 110: ...rain valve 1 and start the filling process by actuating the pump button Note As an alternative to filling the engine with coolant using a pump the filler necks 4 can be used for this purpose D During...

Page 111: ...s must not be bled while the cooling system is being topped up Danger If in an exceptional case it is necessary to check the coolant level with the engine hot due to run ning first carefully loosen th...

Page 112: ...ble 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 D In order to achieve this a pressure valve 1 i...

Page 113: ...r 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 Mount air filter Slide the new air filter 1 onto the intake...

Page 114: ...of crushing The V ribbed belt tensioner is under spring pre tension secure against spring back D Rotate the tensioning pulley of the V ribbed belt tensioner 1 clockwise up to the stop and hold D Remov...

Page 115: ...immediately and rem edy 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...

Page 116: ...mm Swept volume 16 160 cm3 Compression ratio 17 1 Rating 882 KW 1200 hp at 2300 rpm Firing order 1 5 7 2 6 3 4 8 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Valve timing Intake opens 2...

Page 117: ...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 allowe...

Page 118: ...wept volume 24 243 cm3 Compression ratio 17 1 Rating 1324 KW 1800 hp at 2300 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Valve timing Intake...

Page 119: ...0 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: ...wept volume 24 243 cm3 Compression ratio 17 1 Rating 1213 KW 1650 hp at 2300 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Valve timing Intake...

Page 121: ...0 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: ...volume 24 243 cm3 Compression ratio 17 1 Rating 1140 KW 1550 hp at 2300 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Valve timing Intake open...

Page 123: ...0 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: ...volume 24 243 cm3 Compression ratio 17 1 Rating 1029 KW 1400 hp at 2300 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Valve timing Intake open...

Page 125: ...0 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: ...me 24 243 cm3 Compression ratio 17 1 Rating 1029 KW 1400 hp at 2100 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Valve timing Intake opens 24...

Page 127: ...0 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: ...enoid switch defective D D D D D D D D Internal damage to engine piston seized possibly caused by water in fuel D D D D D Fuel quality not in accordance with specifications or fueled severely contamin...

Page 129: ...loss of power Blue smoke White smoke Knocking in the engine Engine too loud Reason D Oil in sump too thin mixed with condensation or fuel D Engine cold D D Engine coolant or intake air still to cold...

Page 130: ...er control MPC 75 Tachometer CAN Master 30 Operation monitoring system 24 102 CAN Bus controlled display devices 29 Emergency operation unit 92 Engine room panel 26 External LC Display 28 Main fuses 9...

Page 131: ......

Page 132: ...MAN Truck Bus AG Vogelweiherstra e 33 90441 N rnberg Germany A member of the MAN Group Printed in Germany 51 99493 8578...

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