Man V8-1000 Page 2 Installation And Operating Instructions Manual Download

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Summary of Contents for V8-1000

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Page 3: ...ng Instructions MAN Marine Diesel Engines for light duty not classified V8 1000 V8 1200 V12 1400 V12 1550 V12 1650 V12 1800 V12 1900 Emission Status EPA Tier 3 51 99493 8596 Translation of the original instructions Version 03 ...

Page 4: ...apters Subject to technical alterations in the interests of further development Reprinting copying or translation even of extracts is not allowed without the written approval of MAN Truck Bus AG All rights under the copyright law are strictly reserved by MAN 2015 MAN Truck Bus AG Vogelweiherstr 33 90441 Nürnberg Germany Tel 49 911 420 1745 Fax 49 911 420 1932 E Mail Engine Documentation man eu Int...

Page 5: ...arranty conditions 11 1 10 Customer service 11 2 General Safety Instructions 13 2 1 Intended use 13 2 2 Content of the installation and operating instructions 14 2 3 Changes and alterations to the engine 14 2 4 Operator s responsibility 14 2 5 Personnel requirements 15 2 5 1 Qualifications 15 2 5 2 Unauthorised persons 15 2 5 3 Instruction 15 2 6 Personal protective equipment 16 2 7 Specific dange...

Page 6: ... 6 1 2 Safety instructions 41 6 2 Engine installation 42 6 2 1 Interfaces between engine and plant 42 6 2 2 Installation Instructions 44 6 2 3 Installation drawing 44 6 2 4 Threaded connections 44 6 3 Completion of the engine and assembly of the equipment set 45 6 3 1 E box terminal box accessibility 45 6 3 2 Mounting a gearbox on the flywheel housing 46 6 3 3 Checking the crankshaft axial clearan...

Page 7: ...ater separator of fuel filters 65 7 3 6 Daily inspection before starting the engine 66 7 4 Starting and stopping the engine 67 7 5 Running the engine for ship operation 68 7 5 1 Operating ranges for marine engines 68 7 5 2 Display systems and instruments 69 7 5 3 Override system 72 8 Maintenance and care 73 8 1 Requirements 73 8 2 Safety instructions 73 8 3 Maintenance schedule 74 8 4 Maintenance ...

Page 8: ... 3 and 6 months 100 10 4 Recommissioning of shutdown engines 102 10 4 1 Commissioning of preserved engines compliant to MAN Works Standard M 3069 102 10 4 2 Commissioning of non preserved engines 103 11 Technical data 105 11 1 Weights and measures 105 11 2 Requirements of assembly location space requirements 105 11 3 Engine data of engines for light duty 106 11 3 1 V8 1000 D2868 LE426 106 11 3 2 V...

Page 9: ...that have been appro ved by MAN Only the genuine spare parts approved by us are tested by us and thus meet the relevant requirements for use of the engine The improvement of the protection of the environment is of special concern to MAN This starts with the development and construction of our engines So we take great care to ensure that no environmentally damaging materials are used in this proces...

Page 10: ...d to serious injury or death if it is not avoided WARNING Describes a potentially dangerous situation that can lead to serious injury or death if it is not avoided CAUTION Describes a potentially dangerous situation that can lead to minor or moderate injury if it is not avoided NOTE Describes a potentially dangerous situation that can lead to damage if it is not avoided Tips and Recommendations Us...

Page 11: ...ligations agreed in the supply contract MAN s general terms and conditions and the legal regula tions in force at the time the contract is signed all apply 1 4 Notes on EPA Regulations NOTE Violation of federal law 40CFR 1068 105 b Therefore S Failing to follow these instructions when installing a certified engine in a vessel violates federal law 40CFR 1068 105 b and is subject to fines or other p...

Page 12: ...een determined specifically for engines Despite con stant market observation we cannot judge the aspects of other products nor can we accept responsibility for them WARNING Risk of injury due to use of incorrect spare parts Incorrect or defective spare parts can lead to damage malfunction or total failure and impair safety Therefore S Only use genuine MAN spare parts User tip Please always quote t...

Page 13: ...to these instructions and all accompanying supplier operating instructions will lead to the loss of claims under the warranty The use of non approved parts leads to the loss of warranty claims Even after the expiry of the warranty period we recommend the continued use of original parts in order to ensure the continuing performance of the engine 1 10 Customer service MAN customer service product su...

Page 14: ...esel engines D2868 LE4 D2862 LE4 12 Diese Anleitung vor Beginn aller Arbeiten sorgfältig durchlesen Dies gilt insbesondere für das Kapitel Allgemeine Sicherheitshinweise und die jeweiligen Sicherheitshinweise in den Kapiteln ...

Page 15: ...e risk is borne entirely by the operator Intended use also includes compliance with the prescribed operating maintenance and repair work The engine may only be used maintained and repaired by persons who are familiar with the engine and have been informed of the hazards Unauthorised changes to the engine absolve MAN of any liability for resulting damage or injury Likewise tampering or changing the...

Page 16: ...field of application must be assured In particular S The operator must be familiar with the applicable industrial safety regulations and additionally determine risks that arise due to the specific working conditions at the engine installation location in a risk assess ment The operator must implement this in the form of operating instructions for operation of the engine S During the entire time th...

Page 17: ...ble to perform work on electrical systems and detect and prevent possible risks based on their tech nical training knowledge and experiences as well as their awareness of the relevant standards and re quirements The qualified electrician is trained for the specific application site at which they are active and is aware of the relevant standards and requirements Only persons who can be expected to ...

Page 18: ...ting work clothes with low tear strength tight sleeves and no protruding parts Its primary purpose is to protect against injury climate effects and dirt Do not wear rings chains or other jewellery whilst working Hard hat to protect against falling or flying parts Safety shoes to protect against heavy falling parts and slipping on slippery surfaces Safety gloves to protect the hands against frictio...

Page 19: ... the electrical system and check that there is no voltage before commencing any work on it S Shut off the voltage supply and prevent it from being switched back on again before commencing maintenance cleaning or repair work S Do not bypass or disable fuses When changing fuses make sure the correct amperage is used S Keep moisture away from live parts as it can cause short circuits Moving parts WAR...

Page 20: ... the danger zone and close proximity S Fire extinguishers must be provided S Report any suspicious substances fluids or gases to the person in charge immediately S Repair leaks S Stop work immediately in the event of a fire Leave the danger zone and do not return until it is safe to do so Coolants water antifreeze corrosion inhibitor WARNING Risk of injury due to hazardous coolants Coolant contain...

Page 21: ...e to noise The noise level in the working area can cause serious hearing damage Therefore S Always wear ear protectors whilst working S Only remain in the danger zone for as long as necessary Sharp Edges and Corners CAUTION Risk of injury on edges and corners Sharp edges and corners can cause skin grazes and cuts Therefore S Always proceed with caution when working hear sharp edges and corners S W...

Page 22: ...ive lines Jet of fluid discharged under high pressure Therefore S Never touch the jet of fluid S Press the emergency off button immediately S If necessary implement further measures to reduce the pressure and stop the jet of fluid S Collect and dispose of discharged fluids in the correct manner S Replace the defective parts WARNING Danger to life due to strong magnetic fields Therefore S People wi...

Page 23: ...mergency off device must be freely accessible at all times WARNING Danger to life due to non functioning safety equipment Therefore S Check whether all safety equipment is functioning properly and installed correctly before commencing work S Check whether all safety equipment is functioning properly and installed correctly before starting the engine 2 9 Protective equipment The operator must retro...

Page 24: ... reporting first aid and rescue equipment S Provide regular safety instruction S Keep access routes for rescue vehicles clear In the event of an accident do the right thing S Stay calm S Stop the engine immediately using the emergency off button S Perform first aid S Alert the rescue services and or fire brigade S Assist with getting people out of the danger zone if possible S Make sure the access...

Page 25: ... all safety warning and operating signs and notices are always easily legible S Clean or replace illegible safety warning and operating signs and notices Access forbidden Areas that display this warning must notbe entered Electrical voltage Only qualified electricians are allowed to work in areas that display this sign Unauthorised persons are not allowed to enter areas that display this sign Hot ...

Page 26: ...ons in the various chapters 2 12 Weight data Ensure that when handling the engine and the engine parts listed in the table suitable lifting equipment is used Description Weight kg Crankcase 500 Crankshaft 135 Flywheel 38 Intercooler 54 Engine slides 189 Oil pan 35 Expansion tank 45 Exhaust manifold parts set 26 Gearbox 561 Flywheel housing 30 Expansion tank 45 Resilient coupling with flange bearin...

Page 27: ...ardous substances are inadvertently re leased into the environment S If necessary inform the responsible municipal authorities about the problem The following environmentally hazardous substances are used Lubricants Lubricants and oils contain toxic and environmentally hazardous substances They must not be released into the environment and must be disposed of by a specialist disposal company Diese...

Page 28: ...ine diesel engines D2868 LE4 D2862 LE4 26 Carefully read through the Operating Instructions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters ...

Page 29: ...ety instructions in the various chapters 3 Engine model plate Always quote the engine model engine number and plant number order number in all correspond ence and enquiries You should therefore check the relevant data on the engine model plates and enter it below before first commissioning of the engine The engine model plates 1 and 2 are attached on the crankcase Engine model 3 Engine number 4 Pl...

Page 30: ... designation Explanation Example D Fuel type Diesel 28 Figure 100 128 mm bore 6 Stroke figure rounded 157 mm stroke 8 or 2 Number of cylinders 8 or 12 cylinders L Turbocharging with turbocharger and intercooler E Engine installation Marine engine 4 Model designation identification Development number 3 3 Data on the engine model plate Please always quote the engine model engine number and order num...

Page 31: ... system High pressure common rail injection system in conjunction with EDC7 Electronic Diesel Control Fuel system Low pressure system consisting of fuel lines the hand pump and the fuel filters High pressure system consisting of the volume controlled high pressure pumps flange mounted fuel pumps and the rails with rail pressure sensor and pressure limiting valve Engine Lubrication Force feed lubri...

Page 32: ...housing and flywheel The flywheel housing is provided with a connection in accordance with SAE1 Various flywheel versions can be supplied depending on the type of application e g for flange mounting of a gearbox or for mounting of a flexible jointed shaft coupling Starter The electric starter is double pole insulated The starter can be mounted either on the left or the right of the engine Alternat...

Page 33: ...rk This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters 4 3 Engine views 4 3 1 Front left view The picture shows an D2862 LE4 engine with 1 stage turbocharching example 1 Exhaust manifold 2 EDC Box 3 Oil filler neck 4 Oil filter 5 Oil dip stick 6 V belt guard 7 Air cleaners ...

Page 34: ...rting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters 4 3 2 Rear right view The picture shows an D2862 LE4 engine with 1 stage turbocharching example 1 Exhaust pipe liquid cooled 2 Fuel pre filter with hand priming pump 3 Flywheel 4 Sea water pump ...

Page 35: ...rmation in this chapter Strictly observe these instructions and act prudently to avoid accidents personal injury and property dam age Personal Protective Equipment The following protective equipment must be worn S Protective workwear S Hard hat S Safety shoes S Safety gloves 5 2 Safety instructions Heavy Suspended Loads WARNING Danger to life due to suspended loads Loads can swing out and fall dur...

Page 36: ...ipment S Handle packages carefully and note the symbols and instructions on the packaging S Use lifting gear Angle of incline is not permitted Swinging loads WARNING Risk of injury due to swinging packages Package can cause injury and damage Therefore S Ensure that during the transport of packages no persons objects or obstacles are in the swinging range of the items being transported Unauthorised...

Page 37: ...heck the delivery for missing items and for damage from transport If external signs of transport damage are apparent S Do not accept delivery or only accept under written protest S List scope of damage on the transport documents or on the transportation company s packaging slip S Initiate a claims process User tip Make sure to claim each damage case as soon as it is discovered Damage claims can on...

Page 38: ... Transport 5 4 1 Engine without gearbox Lifting Points For lifting the engine 4 crane hook lugs 3 are mounted on the engine Use sufficiently dimensioned crane lifting gear 1 to lift the engine Cables ropes and chains 2 must exert vertical tension tolerance 5_ on the crane hooks DANGER Falling loads weighing up to 2500 kg can lead to serious accidents Therefore S Use crane lifting gear to lift the ...

Page 39: ...fting Points For lifting the engine with gearbox there are 2 crane hook lugs mounted on the gearbox 4 and 2 crane hook lugs mounted on the engine 3 Use sufficiently dimensioned crane lifting gear 1 to lift the engine Cables ropes and chains 2 must exert vertical tension tolerance 5_ on the crane hooks DANGER Falling loads weighing up to 3500 kg can lead to serious accidents Therefore S Use crane l...

Page 40: ...permitted Transport with Crane The engine can be transported with a crane under the following conditions S The crane and the lifting equipment must be designed for the weight of the engine S Cables ropes and chains must not exert diagonal tension on the crane hooks S The operator must be qualified for operating the crane 1 Attach the ropes straps or multipoint lifting equipment according to the pi...

Page 41: ...d statutory regulations ENVIRONMENTAL NOTE Risk to the environment due to incorrect disposal of packaging materials Dispose of packaging materials in an environmentally responsible manner Observe the locally applicable disposal regulations Enlist the help of a specialist company to deal with disposal if necessary 5 6 Storage Storage of packages Store packages under the following conditions S Do no...

Page 42: ...arine diesel engines D2868 LE4 D2862 LE4 40 Carefully read through the Operating Instructions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters ...

Page 43: ... The installation and commissioning may only be performed by MAN employees or by MAN trained qualified personnel WARNING Danger caused by faulty installation and commissioning Installation and commissioning require trained qualified personnel with sufficient experience Faulty in stallation can cause life threatening situations and considerable property damage Therefore S Installation and commissio...

Page 44: ...ons in the various chapters 6 2 Engine installation 6 2 1 Interfaces between engine and plant 1 Exhaust system 2 Intake system 3 Engine mounts 4 Sea water outlet 5 Engine cooling system 6 Intercooling system The following assembly work must be performed at the interfaces between engine and plant when installing the engine 1 Mount exhaust system see page 52 3 Assemble the resilient engine mounts se...

Page 45: ...he safety instructions in the various chapters 1 Exhaust system 2 Fuel system 3 Auxiliary power take off 4 Flywheel 5 Sea water inlet 6 Electrical system 7 Lube oil system The following assembly work must be performed at the interfaces between engine and plant when installing the engine 1 Mount exhaust system see page 52 2 Connect fuel system see page 50 4 Mount clutch gearbox see page 46 5 Connec...

Page 46: ... connection dimensions In addition depending on the scope of delivery circuit diagrams arrangement drawings for resilient engine mounts etc may also be required which can be obtained from MAN See page 2 for the contact address NOTE Engine installation is based on the installation instructions and the installation drawing Therefore S Please observe these sources of information for all of the follow...

Page 47: ...is enough space available for the regular maintenance work specified in the maintenance schedule 6 3 1 E box terminal box accessibility DANGER Danger to life due to incorrectly installed safety equipment Safety equipment is not accessible Therefore S In an emergency it must be possible to stop the engine quickly and reliably in the engine room S Die rote Notstopptaste am Klemmenkasten muss schnell...

Page 48: ...ons in the various chapters 6 3 2 Mounting a gearbox on the flywheel housing Flywheel The connection dimensions for the flywheel 1 are indicated on the installation drawing S Remove oil grease and preservative from the flywheel Flywheel housing User tip For bolt tightening torques see page 56 Details of the dimensions for the flywheel housing 1 and the type of threaded connections for mounting the...

Page 49: ...the crankshaft axial clearance using a dial gauge held on a magnetic stand before and after flange mounting add on parts S Remove the V belt guard S Position the dial gauge holder 1 with dial gauge 2 on the engine mounting so that the dial gauge tracer pin is resting on the vibration damper with a preload S Press crankshaft all the way in the axial direc tion to the flywheel housing S Zero the dia...

Page 50: ...tment 4 Mounting bolt for engine mounting M 20 S Put the propulsion system on the engine found ation with resilient mounts Ensure that the mounts are arranged correctly shore hard ness S Bolt the engine mountings and the gearbox mountings to the resilient mounts Assignment of the resilient mounts to the engine and gearbox Engine model Gearbox arrangement MAN part number Shore hard ness V8 Flange m...

Page 51: ...tallation drawing specifies the implementa tion of the coolant connections S Connect 1 coolant inlet S Connect 2 coolant outlet 6 5 2 Gearbox oil cooler The coolant is supplied to the gearbox oil cooler via the connection 1 on the sea water pump The coolant feed to the gearbox oil cooler is marked out The connection for the coolant return from the gearbox cooler is to be installed by the shipyard ...

Page 52: ...tions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters 6 6 Connecting the fuel lines 6 6 1 Connecting the fuel lines S Connect the fuel feed 1 S Connect the fuel return 2 For hose connections see installation drawing on page 113 ...

Page 53: ...ns impair water separation There must be sufficient space available for catch ing the separated water and for changing the filter cartridges H approx 200 mm The changeover lever must be easily accessible and freely movable Mounting bolts M10 hexagon bolts or M10 socket head bolts each with DIN 125 10 5 washers Connecting the fuel pre filter To connect the fuel hoses of the tank fuel pre fil ter an...

Page 54: ...ks are combined in a central ex haust outlet The exhaust manifold for the exhaust outlet can be swivelled upwards 1 or rearwards 2 by 90 The dimensions of the flange for connecting the ship s exhaust system can be found on the installa tion drawing see page 113 A pipe elbow with subsequently falling exhaust line gooseneck in the piping prevents water from getting into the engine when reversing or ...

Page 55: ... Connection between the exhaust system and the engine Elastic connecting elements have to be installed between the engine and the exhaust system which permit engine motion to take place due to the elastic engine mounting and decouple the en gine vibration from the exhaust system Example compensator 1 NOTE Component damage due to the effect of forces on the turbocharger Therefore S Exhaust pipes ar...

Page 56: ...ns of grounding cable In the case of dual engine plants each engine requires independent wiring i e the engines circuits must not be linked with each other Batteries Separate batteries are to be provided for the starters for each engine The on board 24V direct current consumer items are to be supplied from their own individual batteries Starter All MAN marine engine starters are of double pole des...

Page 57: ...onsumers are to be charged independently of this a second alternator 2 optional can be mounted The two alternators are not double pole insulated In order to ensure isolated potential free wiring the entire mounting of the alternators on the en gine is isolated The housing for the alternators is therefore connected to the negative terminal of the relevant battery 3 Engine models V8 V 12 Alternator ...

Page 58: ...ing torque in Nm at 8 8 8 at 10 9 10 at 12 9 12 M4 2 5 4 0 4 5 M5 5 0 7 5 9 0 M6 9 0 13 0 15 0 M7 14 0 20 0 25 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 M14x1 5 125 0 185 0 215 0 M16 180 0 260 0 310 0 M16x1 5 190 0 280 0 330 0 M18 260 0 370 0 4...

Page 59: ...ng system S Starting the engine S Performing a test drive including measuring and recording important data Performing initial commissioning requires specific know how on the part of the personnel as well as specific equipment First commissioning may therefore only be performed by persons or workshops authorised and certified by MAN Nuremberg Marine Engines department NOTE Incorrectly performed fir...

Page 60: ...rine diesel engines D2868 LE4 D2862 LE4 58 Carefully read through the Operating Instructions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters ...

Page 61: ...workwear S Safety shoes S Safety gloves 7 2 Safety instructions Personnel Operation of the engine may only be performed by instructed personnel or by trained qualified personnel Ground Rules WARNING Danger due to incorrect operation Incorrect operation can lead to serious injury and or damage Therefore S Perform all operating steps as indicated in these instructions S Before commencing work ensure...

Page 62: ...r faults can be detected at an early stage and major engine damage prevented User tip The causes of engine damage are often small faults which can lead to a chain reaction and res ult in severe engine damage and even eventually result in the total failure of the engine Therefore S Carry out regular simple visual and functional inspections S Eliminate minor faults immediately The basic prerequisite...

Page 63: ...specified by the system manufacturer 2 Open the shut off valves in the fuel feed ENVIRONMENTAL NOTE Do not let fuel spill while filling Do not let fuel leak out onto the ground or into bodies of water 7 3 2 Checking and topping up the coolant DANGER Risk of scalding The coolant is hot Therefore S Only check the coolant level with the engine cooled down NOTE Engine damage due to lack of antifreeze ...

Page 64: ... S The engine cooling system must be filled with a mixture of potable mains water and antifreeze based on ethylene glycol corrosion inhibitor S Screw the cap 1 as far as the stop but do not tighten it Overtightened caps can not be opened again If the cooling system is opened when the engine is at operating temperature there will be pressure loss in the cooling system On continuing engine operation...

Page 65: ...supply has collected in the oil pan Therefore S Carry out an engine oil level check with the engine horizontal and approx 5 minutes after the engine has been switched off Stop the engine Check the oil level after around 5 minutes S Pull out the oil dipstick 1 S Oil dipstick 1 with a clean lint free cloth S Oil dipstick 1 as far as the stop S Pull out the oil dipstick 1 again The oil level should l...

Page 66: ... to incorrect oil quantity Engine damage Therefore S Never add more than the specified oil quantity S Ensure that the oil level is correct S Observe the Min Max mark on the oil dipstick ENVIRONMENTAL NOTE Do not let engine oil spill while filling Do not let engine oil leak out onto the ground or into bodies of wa ter S Unscrew the cap 1 S Pour in fresh engine oil at the oil filler neck 1 The oil l...

Page 67: ...rt and water in the fuel cause Incorrect combustion Injection system damage Piston damage Irreparable engine damage Therefore S Carry out maintenance on the fuel pre filter regularly according to the amount of water used and in accordance with the manufacturer s instructions Drain the water from the fuel pre filter water separator S Drain plugs 1 S Let the accumulated water drain into a suitable c...

Page 68: ...eneral Safety Instructions section and the safety instructions in the various chapters 7 3 6 Daily inspection before starting the engine Daily visual and functional inspections should be carried out S Oil leakage S Coolant leakage S Condition of V belts S Loose and defective parts loose threaded connections With the engine running S Unusual noise S Generation of smoke ...

Page 69: ...n an emergency When the engine is stopped using the emergency stop function there is an entry in the fault memory of the MAN Monitoring and Diagnostic System MMDS Therefore S Do not use the emergency stop function to stop the engine unless there is good reason to do so S Shutting off the voltage supply to the EDC engine management using the battery master switch when the ignition is switched on is...

Page 70: ...he load by increasing the rpm S Speed less than 100 of the rated speed S If there is prolonged operation with overload a warning is output via the MMDS S Continuous operation is allowed for heavy operating mode S Continuous operation is not allowed for medium and light operating modes 2 Normal operation S Continuous operation allowed limit speed 100 to 102 of rated speed 3 As new condition S Opera...

Page 71: ...he recorded measured values in the form of digital displays and circular gauges For further graphic pages see page 72 If a value reaches a critical level a warning message or an alarm is tripped and shown on the display de pending on importance 2 If the value exceeds certain plausible limits a sensor fault is displayed An in tegrated buzzer emits a warning sound each time a new alarm message is is...

Page 72: ...MDS CLC 6 5 Several graphic pages depict the recorded meas ured values in the form of digital displays and cir cular gauges The numeric values on the digital instruments are coloured to indicate their alarm status Instrument page 1 rpm fuel consumption coolant temperature engine oil pressure Instrument page 2 rpm throttle lever position load fuel pressures charge air temperature charge air pressur...

Page 73: ...page 4 rpm trip consumption gear oil temperature gear oil pressure coolant pressure coolant pressure in expansion tank A separate alarm table lists all pending alarms with detailed information For commissioning and ser vice there is a service page available on which the engine and gearbox data as well as all sensor alarm states can be viewed at a glance Alarm page the last alarm that occurred is a...

Page 74: ...re the engine power The override system allows the original engine power to be restored In dangerous situations it is thus possible to activate the full engine power and therefore ensure the ship s safety NOTE Risk of engine damage caused by ignoring alarms Therefore S The override system is only allowed to be used in emergencies Remedy the cause of an alarm MAN accepts no liability for engine dam...

Page 75: ... Ground rules WARNING Risk of injury due to incorrectly performed maintenance For this reason S Shut down engine before performing maintenance S Ensure that the engine cannot be started by unauthorised persons S Perform all maintenance steps as indicated in these instructions S Ensure adequate work space before starting any work S Make sure the working area is kept clean and orderly NOTE MAN accep...

Page 76: ... oil observe the health protection precautions Filter inserts and filter cartridges S Filter inserts and filter cartridges such as oil and fuel filters are regarded as hazardous waste and must be disposed of correctly Observe the regulations of the responsible local authorities Batteries S Used batteries contain hazardous substances Batteries must be taken back by the distributor and properly disp...

Page 77: ...ructions section and the safety instructions in the various chapters 8 4 Maintenance work 8 4 1 Engine oil change WARNING Risk of injury due to hot oil Engine oil reaches high temperatures during operation and causes scalding if touched For this reason S Always wear protective gloves when holding oil drain plugs User tip Use a container with a capacity of at least 100 litres when changing the oil ...

Page 78: ...plied by MAN is required for pumping the oil out of the oil pan 1 Oil in button 2 Oil out button 3 Flow direction marking 4 Hose coupling for connecting to engine Supply voltage 24 V 1 Unscrew the cap 3 2 Connect the suction line 2 of the oil drain pump to the oil drain hose 3 of the engine 3 Connect the power supply of the electric oil suction and filling pump to the plug 4 4 When the engine is a...

Page 79: ...th high performance diesel engine oil to Works Standard M3277 NOTE MAN accepts no liability for material defects caused by the use of non approved fuels lubric ants and coolants No liability for material defects can be accepted if non approved fuels lubricants and coolants are used For this reason S Only use approved fuels lubricants and coolants see the publication entitled Fuels Lubricants and C...

Page 80: ...a canister 1 Slowly pour in the entire oil quantity through the filler neck 2 Wait around 20 minutes for the cold engine oil to collect in the oil pan 2 Pull out the oil dipstick 1 and check the oil level The oil level must be between the two notches on the dipstick MIN MAX Fill engine oil using the electric oil change pump An electric oil change pump 2 can be used to fill the engine oil pan also ...

Page 81: ... An electrically operated oil suction and filling pump which can be supplied by MAN is required for pumping the oil out of the oil pan 1 Oil in button 2 Oil out button 3 Flow direction marking 4 Hose coupling for connecting to engine Supply voltage 24 V 1 Unscrew the oil drain plug cap 3 2 Connect the suction line 2 of the oil drain pump to the oil drain hose 3 of the gearbox 3 When the machine is...

Page 82: ... Stop work immediately in the event of a fire Leave the danger zone and do not return until it is safe to do so NOTE Risk of damage due to dirt particles Risk of component damage due to dirt in the fuel system For this reason S Ensure complete cleanliness when working on the fuel system ENVIRONMENTAL NOTE The emerging fuel must not be allowed to pass into the ground or into sources of water Cleani...

Page 83: ... the filter cup 2 and fuel filter cartridge 1 4 Clean the filter cup 2 5 Coat new seals with fuel 6 Screw on a new fuel filter cartridge 1 with a new seal until the seal makes contact 7 Tighten the fuel filter cartridge 1 by hand by a 3 4 turn 8 Tighten the filter cup 2 with new seal Tightening torque 20 Nm 9 Connect the electrical connection 3 10 Bleed the fuel system see page 85 NOTE MAN accepts...

Page 84: ...s to the General Safety Instructions section and the safety instructions in the various chapters Fuel filter on engine changing the fuel filter cartridge A two stage fuel filter is fitted in the engines 1 Arrangement of the two stage fuel filter on en gines with one stage turbocharging 2 Arrangement of the two stage fuel filter on en gines with two stage turbocharging ...

Page 85: ...n the various chapters Drain the fuel from the filter ENVIRONMENTAL NOTE Do not let fuel spill while draining Do not let fuel leak out onto the ground or into bodies of water Use a container with a capacity of 3 litres to collect the fuel 1 Open the bleed screws 1 2 Unscrew the drain screws 2 and collect the emerging fuel in a container 3 Close the drain screws 2 Tightening torque 3 4 Nm 4 Close t...

Page 86: ...pters Change the fuel filter cartridge 1 Undo and unscrew the filter cup 1 using an oil filter wrench 2 Remove the fuel filter cartridge 2 from the hou sing NOTE MAN accepts no liability for material defects caused by the use of non approved spare parts MAN accepts no responsibility for damage caused by the installation of spare parts of non MAN origin For this reason S Only use genuine MAN spare ...

Page 87: ...r cup 4 then fit a new O ring 5 and screw into the housing Tightening torque 25 30 Nm Change the two stage fuel filter s second fuel filter cartridge 8 4 3 Bleeding the fuel system 1 Undo the bleed screws 1 2 Loosen the plunger 2 of the hand pump 3 3 Actuate the plunger 2 of the hand pump until fuel emerges at bleed screws 1 without bubbles 4 Tighten the bleed screws 1 Tightening torque 25 30 Nm 5...

Page 88: ...plug User tip Use a container with a capacity of at least 100 litres when changing the coolant ENVIRONMENTAL NOTE Dispose of refrigerant and refrigerant oil correctly Draining the cooling system Only drain the cooling system when the engine has cooled down as follows S Open the cover 1 of the filler neck onthe expansion tank S Unscrew the protective cap from the drain filler valve 2 S Connect the ...

Page 89: ...ore starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters S Unscrew the screw plug 1 on the exhaust manifold on the left engine side and drain the coolant S Screw the screw plug 1 back in and tighten it S Filling bleeding the cooling system ...

Page 90: ... cooling system Therefore S Prepare coolant as specified in the publication entitled Fuels lubricants and coolants for MAN indus trial and marine diesel engines During filling bleed the cooling system through the bleed screws 1 at the liquid cooled exhaust tur bochargers and at the exhaust manifold 2 Engine installed inclined towards flywheel side The bleed screws 1 and 2 are below the coolant lev...

Page 91: ...e cap 3 as far as the stop but do not tighten it Overtightened caps can not be opened again 6 Switch on the pump again until coolant emerges at the bleed screw 1 without bubbles 7 Switch off the pump and tighten the bleed screws 1 8 Switch on the pump again until coolant emerges at the bleed screw 2 without bubbles 9 Switch off the pump and tighten the bleed screws 2 10 Unscrew the pump filler hos...

Page 92: ...cap User tip Do not open the cooling system when the engine is at operating temperature Pressure will be lost in the cooling system If the cooling system is opened when the engine is at operating temperature this can cause a Pressure in expansion tank alarm and reduced engine power when the engine is then operated The coolant pressure in the expansion tank only builds up again after the engine has...

Page 93: ...ty Instructions section and the safety instructions in the various chapters 8 4 5 Changing the air filter Removing the air filter S Undo the hose clamp 2 S Remove the air filter 1 from the intake neck 3 The second air filter is removed in the same way Mounting the air filter S Push the new air filter 1 onto the intake neck 3 S Position the hose clamp 2 and tighten it Tightening torque 7 Nm ...

Page 94: ...oly V belts for cracks fouling by oil overheating and wear S Replace damaged poly V belts 8 4 8 Changing poly V belts CAUTION Risk of injury due to spring tension Springing back of the poly V belt tensioner For this reason S Brace the poly V belt tensioner to prevent it from springing back unintentionally S Turn the poly V belt tensioner tensioning pulley 1 clockwise as far as the stop and hold it...

Page 95: ...n the engine external cleaning Engine damage is frequently caused by occurrences which at first seem to be unimportant or insignificant Therefore simple visual inspection can be used to detect impending faults at an early stage Cleanliness is a prerequisite for faultless operation Visually inspect hose connections Check the coolant hoses for S Leakage of coolant or sea water S Firm seating of the ...

Page 96: ...diesel engines D2868 LE4 D2862 LE4 94 Carefully read through the Operating Instructions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters ...

Page 97: ...tem can reduce the power output of the monitored engine to pre vent follow on damage The MAN Monitoring and Diagnostics System can stop the monitored engine autonomously if machine op eration is endangered by a technical defect To ensure vessel safety in dangerous situations the override system provides an option for preventing the engine from being stopped or the power from being reduced and for ...

Page 98: ...rtance If the value ex ceeds certain plausible limits a sensor fault is displayed An integrated buzzer emits a warning sound each time a new alarm message is issued This sound can be stopped at the push of a button A separate alarm table lists all pending alarms with detailed information Examples of alarms are shown on the illustration opposite The system makes a distinction between S Alarm e g ED...

Page 99: ...s in the various chapters Display in cover of E box in engine room The display 2 in the cover of the E box 1 is used for visual indication of engine alarms Navigation through the various monitoring and alarm pages is possible using the buttons directly on the display The language desired system of units date time and display contrast can be set by means of screen menu In the event of an alarm the ...

Page 100: ...engines D2868 LE4 D2862 LE4 98 Carefully read through the Operating Instructions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters ...

Page 101: ...t The following protective equipment must be worn S Protective workwear S Safety shoes S Safety gloves 10 2 Safety instructions Personnel The decommissioning and recommissioning of an engine must only be carried out by trained specialist per sonnel Ground Rules WARNING Risk of injury and damage due to untrained personnel Therefore S Ensure that the engine cannot be started be unauthorised persons ...

Page 102: ...can necessitate the complete dismantling of the engine Therefore S Observe measures for corrosion protection 10 3 1 Decommissioning of the engine for up to 3 months Simple precautions taken before the temporary decommissioning of the engine provide effective corrosion protection S Thoroughly clean the external surfaces of the engine using compressed air Thoroughly dry the sur faces S Fill the fuel...

Page 103: ...d up engine with corrosion inhibiting fuel for 3 minutes at rated speed S Operate the engine for 2 minutes at idle S Stop the engine S Close off the openings for suction air and exhaust gas and seal them air tight with the engine still warm NOTE Damage to property due to incorrect preservation When the engine is cranked with the starter the engine may not start so as to allow the combustion chambe...

Page 104: ...ther actions a complete dismantling of the engine A distinction must therefore be made between the commissioning procedures of preserved and non pre served engines 10 4 1 Commissioning of preserved engines compliant to MAN Works Standard M 3069 1 Remove external preservation Never use a high pressure cleaner for this 2 Remove caps from intake and exhaust openings 3 Check the cooling system add ant...

Page 105: ...and install injectors to do this Check valves for free movement check valve clearance and adjust as necessary Replace defective corroded parts 2 Drain old oil from engine and change oil filter Fill engine with fresh approved engine oil 3 Check cooling system for corrosion check coolant for proper concentration if in doubt change coolant Before adding new coolant clean coolant chambers and remove i...

Page 106: ...marine diesel engines D2868 LE4 D2862 LE4 104 Carefully read through the Operating Instructions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters ...

Page 107: ... turbocharching Specification V8 1000 D2868 LE426 V12 1550 D2862 LE426 V12 1400 D2862 LE446 Unit Weight dry 1780 2270 kg A 1736 2124 mm B 1153 1153 mm C 1236 1290 mm Engines with 2 stage turbocharching Angabe V8 1200 D2868 LE436 V12 1800 D2862 LE436 V12 1900 D2862 LE476 V12 1650 D2862 LE456 Unit Weight dry 1875 2365 2365 2365 kg A 1745 2140 2140 2255 mm B 1153 1153 1153 1150 mm C 1222 1275 1275 13...

Page 108: ...ng mode Up to 1000 operating hours per year at a maximum of 20 of time at full load and an average load of 50 Rating D2868 LE426 735 kW 1000 hp at 2300 rpm Max torque D2868 LE426 3340 Nm at 1300 2100 rpm Ignition sequence DIN 73021 1 5 7 2 6 3 4 8 cylinder arrangement see page 111 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Fuel system High pressure pump Bosch CP 3 4 Injection syste...

Page 109: ...operating hours per year at a maximum of 20 of time at full load and an average load of 50 Rating D2868 LE436 882 kW 1200 hp at 2300 rpm Max torque D2868 LE436 4010 Nm at 1200 2100 rpm Ignition sequence DIN 73021 1 5 7 2 6 3 4 8 cylinder arrangement see page 111 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Fuel system High pressure pump Bosch CP 3 4 Injection system Common rail Gover...

Page 110: ...r year at a maximum of 20 of time at full load and an average load of 50 Rating D2862 LE426 1140 kW 1550 hp at 2300 rpm D2862 LE446 1029 kW 1400 hp at 2300 rpm Max torque D2862 LE426 5180 Nm at 1200 2100 rpm D2862 LE446 4680 Nm at 1200 2100 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 cylinder arrangement see page 111 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Fuel system High press...

Page 111: ... per year at a maximum of 20 of time at full load and an average load of 50 Rating D2862 LE436 1324 kW 1800 hp at 2300 rpm D2862 LE456 1213 kW 1650 hp at 2300 rpm Max torque D2862 LE436 6010 Nm at 1200 2100 rpm D2862 LE456 5510 Nm at 1200 2100 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 cylinder arrangement see page 111 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Fuel system High pr...

Page 112: ...mode Up to 500 operating hours per year at a maximum of 5 of time at full load Rating D2862 LE476 1397 kW 1900 hp at 2300 rpm Max torque D2862 LE476 6220 Nm at 1200 2100 rpm Firing order 1 12 2 11 3 10 6 7 5 8 4 9 cylinder arrangement see page 111 Valve clearance cold engine Intake 0 50 mm Exhaust 0 80 mm Fuel system High pressure pump Bosch CP 3 4 Injection system Common rail Governor Electronic ...

Page 113: ...r Beginn aller Arbeiten sorgfältig durchlesen Dies gilt insbesondere für das Kapitel Allgemeine Sicherheitshinweise und die jeweiligen Sicherheitshinweise in den Kapiteln Cylinder arrangements Cylinder arrangement V8 Cylinder arrangement V12 1 2 3 4 5 6 7 8 2 5 8 9 10 3 4 6 7 1 11 12 ...

Page 114: ...diesel engines D2868 LE4 D2862 LE4 112 Diese Anleitung vor Beginn aller Arbeiten sorgfältig durchlesen Dies gilt insbesondere für das Kapitel Allgemeine Sicherheitshinweise und die jeweiligen Sicherheitshinweise in den Kapiteln ...

Page 115: ...stallation drawings V8 1200 MAN marine diesel engines D2868 LE4 D2862 LE4 113 Identification number for installation drawing 51 00508 7126 drawn on 08 11 2011 12 Installation drawings V8 1200 D2868 LE436 ...

Page 116: ...Installation drawings V8 1200 MAN marine diesel engines D2868 LE4 D2862 LE4 114 Identification number for installation drawing 51 00508 7126 drawn on 08 11 2012 ...

Page 117: ...Installation drawings V8 1200 MAN marine diesel engines D2868 LE4 D2862 LE4 115 Identification number for installation drawing 51 00508 7126 drawn on 08 11 2011 ...

Page 118: ...Installation drawings V8 1200 MAN marine diesel engines D2868 LE4 D2862 LE4 116 Identification number for installation drawing 51 00508 7126 drawn on 08 11 2012 ...

Page 119: ...Installation drawings V8 1200 MAN marine diesel engines D2868 LE4 D2862 LE4 117 Identification number for installation drawing 51 00508 7126 drawn on 08 11 2011 ...

Page 120: ...Installation drawings V8 1200 MAN marine diesel engines D2868 LE4 D2862 LE4 118 Identification number for installation drawing 51 00508 7126 drawn on 08 11 2012 ...

Page 121: ...tallation drawings V12 1800 MAN marine diesel engines D2868 LE4 D2862 LE4 119 Identification number for installation drawing 51 00512 7136 drawn on 22 10 2012 13 Installation drawings V12 1800 D2862 LE436 ...

Page 122: ...Installation drawings V12 1800 MAN marine diesel engines D2868 LE4 D2862 LE4 120 Identification number for installation drawing 51 00512 7136 drawn on 22 10 2012 ...

Page 123: ...Installation drawings V12 1800 MAN marine diesel engines D2868 LE4 D2862 LE4 121 Identification number for installation drawing 51 00512 7136 drawn on 22 10 2012 ...

Page 124: ...Installation drawings V12 1800 MAN marine diesel engines D2868 LE4 D2862 LE4 122 Identification number for installation drawing 51 00512 7136 drawn on 22 10 2012 ...

Page 125: ...Installation drawings V12 1800 MAN marine diesel engines D2868 LE4 D2862 LE4 123 Identification number for installation drawing 51 00512 7136 drawn on 22 10 2012 ...

Page 126: ...Installation drawings V12 1800 MAN marine diesel engines D2868 LE4 D2862 LE4 124 Identification number for installation drawing 51 00512 7136 drawn on 22 10 2012 ...

Page 127: ...es D2868 LE4 D2862 LE4 125 Carefully read through the Operating Instructions before starting any work This particularly applies to the General Safety Instructions section and the safety instructions in the various chapters 14Index ...

Page 128: ...res EDC Electronic Diesel Control evtl Possibly Fa Company ggf As necessary h Hour kg Kilogram Term Terminal kW Kilowatt LCD Liquid Crystal Display LED Light Emitting Diode m Metre MAN cats MAN computer assisted testing and diagnostic system MAX Maximum MFR Engine Management Computer MMDS MAN Monitoring and Diagnostic System min Minutes MIN Minimum mm Millimetre Nm Newtonmetre TDC Top Dead Centre ...

Page 129: ... Con sequently a message is essentially available to each CAN bus station for receipt The transfer of a message depends solely on the decision of the control units It is therefore possible for a message to be accepted by one several or all control units for further processing CR common rail Whereas conventional diesel models with direct injection build up the fuel pressure from scratch for each in...

Page 130: ...ystem mounting 49 Copyright 9 Customer service 11 D Data on the engine model plate 28 Decommissioning and recommissioning 99 Description of engine 29 Design and function 29 Display system and instruments Colour display MMDS CLC 6 5 69 Disposal 10 E E box accessibility 45 Emission control information label 28 Engine data D2862 LE426 108 D2862 LE436 109 D2862 LE446 108 D2862 LE476 110 D2868 LE426 10...

Page 131: ...rs Drain water 65 Fuel level checking and topping up 61 Fuel lines connecting 50 Fuel prefilter changing filter cartridge 81 Fuel prefilter cleaning 80 Fuel system Description 29 Fuel system bleeding 85 I Information about these instructions 7 Injection system 29 Installation engine 42 Installation and commissioning 41 Installation drawings V12 1800 117 V8 1200 111 Installation Instructions 44 Int...

Page 132: ...ty Instructions section and the safety instructions in the various chapters S Safety equipment 21 Service centres 95 Signs and notices 23 Spare parts 10 Specific dangers 17 Starter motor 54 Storage 39 T Technical data 105 Transport 36 Transport inspection 35 Transport packaging and storage 33 V Visual inspections 93 W Warranty conditions 11 Weights 24 Weights and measures 105 ...

Page 133: ......

Page 134: ...MAN Truck Bus AG Vogelweiherstraße 33 90441 Nürnberg Germany A member of the MAN Group Printed in Germany 51 99493 8596 ...

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