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Safety regulations

11

General notes

Day-to-day use of power engines and the service products (fuels, lubricants, cool-
ants) necessary for running them presents no problems if the persons occupied
with their operation, maintenance and care are given suitable training and think as
they work.

This summary is a compilation of the most important regulations. These are broken down
into main sections which contain the information necessary for preventing injury to per-
sons, damage to property and pollution. In addition to these regulations those dictated by
the type of engine and its site are to be observed also.

Important:

If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the
eyes etc.,

consult a doctor immediately

.

1. Regulations designed to prevent accidents with injury to persons

During commissioning, starting and operation

D

Before putting the engine into operation for the first time, read the oper-
ating 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 the door of
the engine room prohibiting the access of unauthorized persons and that
you draw the attention of the operating personal to the fact that they are
responsible for the safety of persons who enter the engine room.

D

The engine must be started and operated only by authorized personnel.
Ensure that the engine cannot be started by unauthorized persons.

D

When the engine is running, do not get too close to the rotating parts.
Wear close-fitting clothing.

D

Do not touch the engine with bare hands when it is warm from operation

−

risk of burns.

ËË

D

For safety reasons a separate, functioning red emergency-stop-
button for each engine must be installed at every bridge

(the engine

must stop immediately when the button is pressed once).

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Содержание D 2848 LE 401

Страница 1: ...D 2848 LE 401 403 405 D 2840 LE 401 402 407 D 2842 LE 401 402 403 406 408 411 412 413 ...

Страница 2: ......

Страница 3: ...roved fuels lubricants and coolants are used Note Only use fuel coolants and lubricants in accordance with MAN s regulations otherwise the manufacturer s warranty will not apply For basic information on the fuels see the publication Fuels Lubricants and Coolants for MAN Diesel Engines You can find the approved products in the internet under http www man mn com Products Solutions E Business It is i...

Страница 4: ... operation due to the sew ing machine effect in particular if they are used between parts with different rates of lin ear expansion under heat e g aluminium and cast iron and leaks may then occur Example the cap of the front crankshaft seal If a sealing agent or an adhesive is used here the flat seal will move inwards in the course of time as a result of the different expansion rates of the materi...

Страница 5: ...e views D 2842 LE 401 16 First commissioning 18 Commissioning 20 Starting 21 Operation monitoring system BE1 22 Shutting down 44 Maintenance and care 45 Lubrication system 45 Fuel system 48 Cooling system 51 V belts 54 Alternator 55 Temporary decommissioning of engines 55 Technical data 56 Troubleshooting table 62 Index 64 ...

Страница 6: ...e number Rating speed Note The manufacturer of the complete ready to use machine in which this engine is to be installed must take the further action necessary in the context of indirect safety related engineering and provision of instructions to ensure that the ready to use machine complies with the requirements of the EC directive on machines The engine must not be put into operation until the c...

Страница 7: ...Declaration 9 ...

Страница 8: ...appropriate spaces The engine type plates are on the crank case see illustration Model delivered on installed on Engine serial number Order number MAN Nutzfahrzeuge Aktiengesellschaft Typ Motor Nr Engine No NI II Temp C Werk Nürnberg Germany MAN Nutzfahrzeuge Aktiengesellsc MAN Nutzfahrzeuge Aktiengesellschaft Altitude m Rating BHP Job No Rating kW Speed rpm Serial No Model Year 0219 Aufstellhohe ...

Страница 9: ...idents with injury to persons During commissioning starting and operation D Before putting the engine into operation for the first time read the oper ating 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 the door of the engine room prohibiting the access of unauthorize...

Страница 10: ...e is a risk of burns and scalding Do not touch oil drain plugs or oil filters with bare hands ËË D Take into account the amount of oil in the sump Use a vessel of suffi cient size to ensure that the oil will not overflow D Open the coolant circuit only when the engine has cooled down If opening while the engine is still warm is unavoidable comply with the instructions in the chapter entitled Maint...

Страница 11: ...dditional starting aids e g injection with starting pilot D Use only MAN approved service products fuel engine oil anti freeze and anti cor rosion agent Pay attention to cleanliness The Diesel fuel must be free of water See Maintenance and care D Have the engine maintained at the specified intervals D Do not switch off the engine immediately when it is warm but let it run without load for about 5 ...

Страница 12: ...nflammation of the skin may therefore occur Used engine oil also contains dangerous substances which have caused skin cancer in animal experi ments If the 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 contact with used engine oil D Protect your skin...

Страница 13: ... the ground waterways the drains or the sewers Violations are punishable Collect and dispose of used engine oil carefully For information on collection points please contact the seller the supplier or the local authorities Adapted from Notes on handling used engine oil ...

Страница 14: ...Commissioning and operation 16 Engine views D 2842 LE 401 1 2 3 9 10 11 7 4 5 6 8 12 14 13 15 17 18 16 19 ...

Страница 15: ...nk 5 Oil filler neck 6 Air intake 7 Water pump engine coolant circuit 8 Oil drain plug 9 Oil dipstick 10 Starter motor 11 Exhaust pipe liquid cooled 12 Waste Gate 13 Turbocharger liquid cooled 14 Oil separator valve for crankcase breather 15 Engine cranking device 16 Oil sump 17 Oil cooler 18 Connection for oil pressure sensor 19 Oil filter ...

Страница 16: ...uels lubricants etc Otherwise the manufacturer s warranty will become null and void Filling with fuel Caution Fill the tank only when the engine is switched off Pay attention to cleanliness Do not spill fuel Use only approved fuels see Fuels Lubricants etc Caution Fill the tank only when the engine is switched off Pay attention to cleanliness Do not spill fuel Use only approved fuels see Fuels Lub...

Страница 17: ...isk of frost drain the raw wa ter pump Filling with engine oil Caution Do not add so much engine oil that the oil level rises above the max marking on the dipstick Overfilling will result in damage to the engine The engines are as a rule supplied with out oil Pour oil into engine via filler neck arrow see page 46 For the quantity required see Technical Data Oil ...

Страница 18: ...y approx 20 minutes after the unit has been switched off D Pull out dipstick arrow D wipe it with a clean lintfree cloth D and push it in again up to the stop D Pull out dipstick again The oil level should be between the two notches in the dipstick and must never fall below the lower notch Top up oil as nec essary Caution Do not add so much engine oil that the oil level rises above the max marking...

Страница 19: ...y turn the starter key through to position III Turn key further up to the stop position III The display lamp goes out The starter mo tor is actuated Lube oil pressure must build up at the oil pressure gauge If it does not switch off the en gine immediately For cold engines 20 C move control lever into starting position against stop for maxi mum engine speed Note When starting the cold engine contr...

Страница 20: ...ions independently of the BE1 operation monitor and shows analog operating val ues from the engine During operation the oil pressure in the engine lubrication system must be moni tored If the monitoring devices register a drop in the lube oil pressure switch off the engine immediately Operation monitoring system BE1 Caution If an engine gear box alarm is displayed on the monitoring device the engi...

Страница 21: ...raised The check lamp reduced speed is then illuminated permanently Note on engines with electronically controlled diesel injection EDC After the ignition has been switched on the lamp Fault in the electronic system will come on momentarily lamp check If there is a fault in the electronically con trolled diesel injection system EDC the lamp Fault in the electronic system will be illuminated perman...

Страница 22: ...em BE1 To achieve optimum operational reliability the system distinguishes between sensor fault and real alarm The following sensors are checked for sensor fault and parting of wire D Engine speed D Engine oil pressure D Coolant temperature D Charge air temperature D Coolant level If the signal sent by the sensor is a value which does not occur in practice or if the wire connection is interrupted ...

Страница 23: ...C see page 28 4 Engine room panel MMDS EP see page 35 For operation and speed adjustment MAN provides the following equipment 5 Drive lever control system Mini Marex made by Mannesmann Rexroth see page 36 1 Round instruments MAN can supply the following VDO round instruments for operation monitoring Revolution counter with integrated digital hours of operation counter Oil pressure engine 0 6 bar O...

Страница 24: ...shes between the following types of alarm error messages D Preliminary alarm the corresponding light emitting diode flashes D Main alarm the corresponding light emitting diode flashes light emitting diode Alarm flashes In the case of an engine slow down alarm Engine slow down also flashes In the case of a stop alarm Engine stop also flashes D Sensor fault the corresponding light emitting diode fla...

Страница 25: ...till Function test of the warning lamps If there is no alarm the warning lamps can be tested When the Test key is pressed all the warning lamps must light up Dimming All alarm LEDs are dimmed automatically depending on the ambient brightness A photo electric element integrated in the front plate ensures this Horn test If the Clear horn key is pressed for approx 5 seconds the fitted buzzer as well ...

Страница 26: ...ST 51 27720 7015 Representation of monitor pages The analog engine data provided by the MMDS is distributed on 4 monitor pages On each page the current engine speed is displayed in the top line The 1st page continues with the most important engine data such as oil pressure coolant pressure charge air pressure and oil pressure in the gearbox Other engine and gearbox data as well as ex haust tempera...

Страница 27: ... downwards In a column to the right of this the code and current time are added Al though a warning message without alarm is entered in the alarm screen there is no au tomatic switch to that screen e g in the case of a programmed ship alarm or ship spe cific warning see page 34 The following codes are distinguished Warnings without code Warnings preliminary alarms WA Main alarms AL Sensor error al...

Страница 28: ...DS the RESET key must also be pressed This function is only enabled in the case of a stop alarm at engine standstill and in the case of a slow down alarm below an engine speed of 800 rpm Horn test If the Clear horn key is pressed for approx 5 seconds the built in buzzer sounds System Failure The front plate of the device has a red LED with the description System Failure This is activated in the fo...

Страница 29: ...ion cursor to the left or decrease input value PAGE Standard function Switch to next highest display screen for analog en gine data The page number is indicated in the top left hand side of the display with P1 to P4 Page 4 is followed again by page 1 If this key is pressed while the alarm screen is on display the monitor switches back to the analog engine data from which the alarm screen was origi...

Страница 30: ...be cancelled using the Escape function menu key ALARMS Men All other previously made set tings are not influenced by this Selection of language and units When the menu is opened the current settings are shown highlighted in black A flashing selection cursor marks the language currently set e g English English German French Italian Spanish US GB D F I E The selection cursor can be moved using the M...

Страница 31: ...laced in the second last line To do so the current language and unit settings are confirmed each time with the key Prg The selection cursor can now be positioned using the keys TE S T RESET to set time exit back set time service The function is called up using the PRG key Prg A new page is opened and the current time time date is displayed The selection cursor jumps to Hour set time hour minute se...

Страница 32: ... the following message appears briefly in the display LOAD MMDS SYSTEM TIME If the central unit is switched off engine ignition off nothing is changed and the following message appears NO MMDS TIME RECEIVED The selection cursor then jumps back to the second last line to the item exit Ship specific alarms There is the possibility to connect 11 ship specific alarms or warnings and to generate these ...

Страница 33: ...he keys and of the LCD displays are the same as those on the MMDS LC see operating instructions for MMDS LC Differences to MMDS LC D no ship specific alarms can be programmed D additional Ignition Pre glow plug Note on pre glow plug The pre glow plug is not active in the in line 6 cylinder engine D 2876 LE401 404 as this engine is not equipped with a pre glow system On V engines pre glow can be fi...

Страница 34: ...Operation of the control system Command master Infinitely variable speed adjustment Infinitely variable speed adjustment 3 Max speed Max speed lock Forwards area Gearbox forwards lock 1 2 Neutral 3 Gearbox reverse lock Reverse area 2 Operating field Acoustic signalling device Neutral lock position À In this position the gearbox clutch is disengaged and the power unit is idling Each time the Neutra...

Страница 35: ...e systems COMMAND COMMAND SYN TROL SYNCHRO TROLLING L5 L4 L8 T2 T1 L7 L6 L3 L1 L2 Key Command takeover T1 The Command takeover key occurs only once on the command master The key is permanently illuminated weakly via LED L1 and indicates that the control system is being supplied with voltage The key serves to take over commands onto the relevant control stand The key has two other additional functi...

Страница 36: ...bled If the control lever is shifted from Forwards to Reverse or vice versa during the Warming Up function the Warming Up function stops automatically when position À neutral is reached When position Á gearbox forwards reverse is reached again the gearbox clutch would be engaged again Additional function switch error message to mute The acoustic signal transmitter which is activated for some alarm...

Страница 37: ...he engine speed synchronisation While the function is active LED 4 SYNCHRO shows continuous light As soon as one of the command masters leaves the engine speed range Forwards without terminating the synchronisation beforehand it is switched off automatically In this case the LED SYNCHRO flashes rapidly approx 0 2 seconds on 0 2 sec onds off and the acoustic signal transmitter issues a continuous t...

Страница 38: ...eutral 3 Operating field Reverse area 2 Gear reverse Clutch 100 slip lock Acoustic signalling device Infinitely variable slip adjustment and speed increase Infinitely variable slip adjustment and speed increase Clutch 0 slip grip and max speed when trolling Clutch 0 slip grip and max speed when trolling To enable the trolling function the command master must be in position À Neutral lock The engin...

Страница 39: ... of the Command display indicates which command master is currently in command The Command displays of the other control stands are disabled If the command is requested on this master the Command display flashes If the command master is in the Warming Up function this is indicated by a brief rhythmic extinguishing of the Command display The Command display is present on the system once once for th...

Страница 40: ... continuous light on the command master in command On all other command masters the Command display is off The command is now at this control stand The control system is ready for operation standby Command change between control stands For a command change to a different control stand there are two variants which have to be set using DIP switch I 2 in the setting unit Command change with lever com...

Страница 41: ...r the command on this control stand Consequence The acoustic signal transmitter is silent The Command display shows continuous light The command takeover is complete and the command is now at this control stand Free command change without lever comparison With this variant a control stand change takes place without taking account of the lever position of the command master involved in the command ...

Страница 42: ... load level do not shut it down immediately but allow it to idle about 5 minutes so that temperatures may equalize Set deck switch to Neutral and switch off the engine at the ignition key Remove key from starting lock Danger Ensure that the engine can not be started by unauthorized persons ...

Страница 43: ...re remove the oil drain plugs on the oil sump and the oil filter bowl and allow the old oil to drain off completely Use a vessel of sufficient size to ensure that the oil does not overflow As the oil drain plug is often not accessi ble a manually operated vane pump may be attached to the engine for draining the oil Pump the old oil out of the sump while the engine is still warm Remove oil drain pl...

Страница 44: ...iately Check oil pressure and check that there is no oil leakage Then shut down the engine After about 20 minutes check the oil level D Pull out dipstick arrow D wipe it with a clean lintfree cloth D and push it in again up to the stop D Pull out dipstick again The oil level should be between the two notches in the dipstick and must never fall below the lower notch Top up oil as nec essary Changin...

Страница 45: ...lds D After releasing the clamping bolts Ç remove filter bowls Æ D Renew filter cartridges Ä Thoroughly clean all other parts in cleaning fluid do not allow cleaning fluid to enter the oil circuit D Use new gaskets Å for reassembly of filter bowls Note To prevent the seal Å from twist ing hold the filter bowl Æ firmly when tightening the tensioning screw Ç Caution Used oil filters are classed as d...

Страница 46: ...icants etc see brochure Fuels lubricants etc Otherwise the manufacturer s warranty will become null and void Injection pump Neither the injection pump nor the control unit must be modified in any way If the lead seal is damaged the engine warranty will become null and void Faults We urgently recommend that you have faults in the injection pump rectified only in an au thorized specialist workshop C...

Страница 47: ...as dangerous waste and must be dis posed of accordingly Change over fuel filter Where the changeover type filter is installed the servicing procedure is for the filter side requiring to be shut off with the engine running During continuous oper ation the selector lever should be placed in a position where both filter halves are in operation Caution Do not leave selector lever in any intermediate p...

Страница 48: ...of accordingly Bleeding the fuel system Note To bleed the fuel system switch on the ignition so that the EHAB will be open An arrow on the filter head indicates the direction of fuel flow D Unscrew bleed screw of first filter in direction of flow by one or two turns D Actuate tappet of hand primer until fuel emerges without bubbles D Screw in the tappet of the hand pump again and tighten it D Clos...

Страница 49: ...nce with regulations Drain coolant as follows but only when the engine has cooled down D Briefly open cap À large cap on the filler neck of the expansion tank for pressure compensation D Remove drain plug in crankcase Ã oil cooler housing Â and exhaust manifold Á D Then remove cap À D Drain coolant into a container of ade quate size D Refit screw plugs D Filling bleeding the cooling system 1 2 3 4...

Страница 50: ...e of the loss of cool ant and have it eliminated D Remove cap À large cap D Fill in the coolant slowly D During the filling operation the liquid cooled turbochargers are to be bled For this purpose an oval flange with a bleeder screw Á is located on the rear side of the turbine housing This bleeder screw must remain open until coolant emerges free of bubbles or until the coolant level has reached ...

Страница 51: ...edure until no more coolant can be added Note The turbochargers must not be bled while the cooling system is being topped up Danger If in an exceptional case the coolant level has to be checked in an engine that has reached operating temperature first carefully turn the cap À large cap with safety valve to the first stop let off pressure then open carefully ...

Страница 52: ...move upwards If pressure is maintained after the spring has disengaged a false reading will be ob tained Reading of tension D Read of the tensioning force of the belt at the point where the top surface of the indicator arm À intersects with the scale D Before taking readings make ensure that the indicator arm remains in its position If the value measured deviates from the setting value specified t...

Страница 53: ...ry or pole terminals or the cables D If durig operation the battery charge lamp suddenly lights up stop the engine im mediately and remedy the fault in the electrical system D Do not run the engine unless the battery charge control is in satisfactory order D Do not short circuit the connections of the alternator with those of the regulator or said connections with ground not even by briefly bringi...

Страница 54: ...ders 8 Bore 128 mm Stroke 142 mm Swept volume 14 620 cm3 Compression ratio 13 5 1 Rating see engine nameplate Firing order 1 5 7 2 6 3 4 8 Valve clearance cold engine Intake 0 25 mm Exhaust 0 40 mm Valve clearance changed from engine No 7678 001 Intake 0 50 mm Exhaust 0 60 mm See instruction label on valve cover Valve timing Intake opens 24 before TDC Intake closes 36 after BDC Exhaust opens 63 be...

Страница 55: ...re of injector New nozzle holder 295 8 bar Used nozzle holder 280 8 bar Engine lubrication Force feed Oil capacity in oil sump litres min max deep 12 l 18 l shallow 20 l 24 l Oil change quantity with filter deep 21 l shallow 27 l Oil pressure during operation depend ing on oil temperature oil viscosity class and engine rpm must be monitored by oil pressure moni tors gauges Oil filter Full flow fil...

Страница 56: ...s 10 Bore 128 mm Stroke 142 mm Swept volume 18 270 cm3 Compression ratio 13 5 1 Rating see engine nameplate Firing order 1 6 5 10 2 7 3 8 4 9 Valve clearance cold engine Intake 0 25 mm Exhaust 0 40 mm Valve clearance changed from engine No 7661 035 Intake 0 50 mm Exhaust 0 60 mm See instruction label on valve cover Valve timing Intake opens 24 before TDC Intake closes 36 after BDC Exhaust opens 63...

Страница 57: ... New nozzle holder 295 8 bar Used nozzle holder 280 8 bar Engine lubrication Force feed Oil capacity in oil sump litres min max deep front end sump 14 l 22 l deep rear end sump 26 l 30 l shallow 26 l 30 l Oil change quantity with filter deep front end sump 25 l deep rear end sump 33 l shallow 33 l Oil pressure during operation depend ing on oil temperature oil viscosity class and engine rpm must b...

Страница 58: ...m3 Compression ratio 13 5 1 Rating see engine nameplate Firing order 1 12 5 8 3 10 6 7 2 1 1 4 9 Valve clearance cold engine Intake 0 25 mm Exhaust 0 40 mm Valve clearance changed from engine No 7651 046 Intake 0 50 mm Exhaust 0 60 mm See instruction label on valve cover Valve timing Intake opens 24 before TDC Intake closes 36 after BDC Exhaust opens 63 before BDC Exhaust closes 27 after TDC Fuel ...

Страница 59: ... LE 403 412 413 six hole nozzles Opening pressure of injector New nozzle holder 295 8 bar Used nozzle holder 280 8 bar Engine lubrication Force feed Oil capacity in oil sump litres min max deep 24 l 32 l semi shallow 22 l 30 l for 38 45 tilt 37 l 45 l Oil change quantity with filter deep 35 l semi shallow 33 l for 38 45 tilt 48 l Oil pressure during operation depend ing on oil temperature oil visc...

Страница 60: ...densation in fuel D D D D Air filter clogged D Electric circuit interrupted D Batteries flat D Starter solenoid switch defective D D D D D Start of delivery not correct incorrectly set D Injection nozzles clogged D Internal damage to engine piston seized possibly caused by water in fuel D D D Fuel quality not in accordance with specifications or fueled severely contaminated D Lower idling speed se...

Страница 61: ...expansion tank radiator defec tive or leaking D Temperature gauge defective D Coolant pipes leaking blocked or twisted D Oil level in sump too low D Engine temperature too high D Oil filter clogged D D Oil pressure gauge defective D D Selected oil viscosity not suitable for ambient temperature oil too thin D Oil in sump too thin mixed with condensation or fuel D Engine cold D D Engine coolant or i...

Страница 62: ...ure 49 Fuel system 48 50 I Injection pump 48 Instructions 6 L Lubrication system 45 48 M Maintenance and care 45 55 N Nameplates 10 O Operation monitoring Display device MMDS L 26 Display device MMDS LC 28 Drive lever control system Mini Marex 36 Engine room panel MMDS EP 35 Round instruments 25 Operation monitoring system 22 24 R Raw water pump 19 Refilling with oil 46 S Safety regulations 11 15 ...

Страница 63: ......

Страница 64: ...Printed in Germany 51 99598 8498 MAN Nutzfahrzeuge AG Geschäftseinheit Motoren Vogelweiherstraße 33 D 90441 Nürnberg Ein Unternehmen der MAN Gruppe ...

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