Man V8-1200 Installation Instructions Manual
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Man V8-1200 Installation Instructions Manual

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Summary of Contents for Man V8-1200

  • Page 3: Foreword

    If you intend to modify a built−in engine component which has been acceptance−tested by MAN, you must notify MAN in writing as a further acceptance test may be required.

  • Page 4: Table Of Contents

    Contents Page Foreword ................Safety regulations .

  • Page 5: Safety Regulations

    D Do not touch the engine with bare hands when it is warm from operation − risk of burns. Ë Ë Ë Ë D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.
  • Page 6 D Electrical accessories and equipment from other manufactures may only be connected without the approval of MAN to the connections provided for the cu- stomer or shipyard. The control of the engine may be adversely affected and thus may lead to property damage or personal injury and is therefore not permitted.
  • Page 7 D When starting do not use any additional starting aids (e.g. injection with starting pilot). D Use only MAN approved service products (fuel, engine oil, anti freeze and anti corrosion agent). Pay attention to cleanliness. The Diesel fuel must be free of water. See Fuels, Lubricants and Coolants ...".
  • Page 8 Safety regulations 3. Regulations designed to prevent pollution Engine oil and filter elements / cartridges, fuel / fuel filter D Take old oil only to an old oil collection point. D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground. Caution: The drinking water supply could be contaminated.
  • Page 9 Wait at least a minute until the pressure in the rail has dropped before loosening a screw connection − If necessary check the pressure drop in the rail with MAN Cats D Risk of injury! − People with pacemaker must keep at least 20 cm away from the running engine.
  • Page 10 Safety regulations Cleanliness Today modern components of diesel injection consist of high precision parts which are exposed to extreme stresses. The high precision technology requires the utmost cleanliness during all work on the fuel system. Even a particle of dirt over 0,2 mm can lead to the failure of components. The measures described as follows are therefore essential before work begins: Risk of damage from penetration of dirt! D Before working on the clean side of the fuel system clean the engine and the engine...
  • Page 11 Safety regulations Risk of damage from penetration of dirt! D When the clean side of the fuel system has been opened it is not permissible to use compressed air for cleaning D During assembly work loose dirt must be removed with the aid of suitable extractors (industrial type vacuum cleaners) D Use only fluff free cleaning cloths on the fuel system D Clean tools and working materials before starting to work...

  • Page 12: Planning Of Engine Installation

    Planning of engine installation V12−1800 V8−1200...
  • Page 13 Planning of engine installation The engines The figures on page 10 show typical views of the V12 and V8 engines without gearboxes. Currently the following engine models are available for delivery: V12−1800 1324 kW (1800 HP) V8−1200 882 kW (1200 HP) Engine environment −...
  • Page 14 The scope of these documents depend on the delivery scope and will be supplied by the MAN representative in the project stage. Alternatively, these documents can be ordered through the following e−mail address: marinemotor@de.man−mn.com...

  • Page 15: Accessibility Of Engine In Engine Room

    Accessibility of engine in engine room When installing the engine, care must be taken to ensure there is adequate space to perform the regular maintenance work specified in the maintenance schedule. Note: Advantages of easy access: D High engine reliability due to easy inspection and maintenance work D Lower service costs due to reduced time outlays...
  • Page 16 Accessibility of engine in engine room D Changing the oil filters Ä (description in the Operating Instructions) D Pumping off and filling of engine and gearbox (description in the Operating Instructions) An oil drain for the engine and gearbox Å can be supplied optionally (fitted left and right).
  • Page 17 Accessibility of engine in engine room D Draining the coolant É and (Description in the Operating Instructions) D Maintenance of the plate−core heat exchanger D Replacing belts D Replacing starter, alternator And coolant pump D Visual inspection and retightening of bolts and hose connections Distance to bulkhead: D=350 mm Removing the cylinder head cover...

  • Page 18: Engine Foundation

    Engine foundation Requirements of engine foundation D The engine foundation in the ship must be designed to absorb propeller thrust in both directions and transmit it to the hull. D The weight of the drive line and all of the dynamic forces caused by rough seas must be safely absorbed.
  • Page 19 Engine foundation Engine weight The weights of the engines (without gearbox) are given in the following table: Engine weight (dry, without gearbox) in kg V8−1200 1875 V12−1800 2365 The weights are based on the engine without lube oil and coolant. To determine the weight of the engine ready for operation, the weight of the lube oil and coolant must be added.

  • Page 20: Engine Mounting

    Easy height adjustment of the mounts Due to these various requirements, the resilient mounts must be carefully adapted. For this reason MAN has developed resilient mounts that are adapted in their design and their shore hardness to the different types of drive lines.
  • Page 21 Engine mounting Overview of the possible arrangements of the engine and gearbox Engine with flange mounted gearbox: This figure shows a V8−1200 (example) with a flange mounted gearbox. The engine and gearbox brackets are installed. The corresponding resilient engine and gearbox mounts are described on page 20 (for dimensions and drilling pattern see installation drawing).
  • Page 22 Engine mounting Resilient engine and gearbox mounts À Mounting bolt for engine base M 20 Á Height adjustment  Mounting bolts M 20, property class 8.8 à Shipping lock bolts Assignment of the resilient mounts to the engines and gearboxes Engine model / Shore Gearbox...
  • Page 23 Engine mounting Resilient cone engine and gearbox mounts for V8−1200 with integral V−gearbox À Mounting nut for engine base M20 Á Height adjustment  Elongated hole for mounting bolts M18 à Cone mount Ä Supporting disk for engine base Å Designation of the mount according to Shore hardness The installation drawings have information on the dimensions of the mounts and the drilling pattern...

  • Page 24: Engine Room Ventilation

    Engine room ventilation Heating of the engine room During operation, each engine transfers heat from its own hot surfaces into the air in the engine room (convection), in a similar fashion to a radiator heating a room in a building. In addition, but to a much lesser extent, radiated heat dissipates to the surroundings (radiant heat).
  • Page 25 Engine room ventilation Air requirement and air pressure in engine room The air admission into the engine room is ensured by the cross−section and the design of the air inlet openings. Air requirement per engine Engine model Power kW (HP) Speed rpm Air requirement m V 8−1200...
  • Page 26 Engine room ventilation Air ducting, general The openings for the inlet and outlet of air are to be arranged such that a purging affect is created, i.e. the whole engine room is provided with a flow of air. Fresh air inlet to engine room Fresh air should enter along the side of the hull at as high a position as possible ahead of the engine room.

  • Page 27: Crane Transport Of The Engine

    Crane transport of the engine Transporting drive line onto ship Caution: When working on the engine make sure to not step on the engine cover À. Use crane lifting equipment to lift engine. Danger: Using unsuitable lifting equipment that is not strong enough for the load may result in serious accidents/injury! Make sure ropes and chains do not pull...

  • Page 28: Flange Mounting A Gearbox

    This can be carried out by MAN for a fee. The requisite data are to be collected during the project phase in the form of a questionnaire − "Questionnaire on torsional vibration calculation for ship’s drive line".
  • Page 29 Flange mounting a gearbox Flywheel and flywheel housing The following applies for all V8 and V12 engines: À Flywheel with I = 1.9 kgm for flange mounting a gearbox Á Flywheel housing with SAE1 connection Note: To carry out an exact installation inspection, request an installation drawing showing detailed dimensions for the flywheel or flywheel housing.
  • Page 30 Flange mounting a gearbox Flange mounting the gearbox to the flywheel housing The dimensions of the flywheel housing À and type of bolted connections for installing the gearbox can be found in the installation drawing. Note: Tightening torques for screws, see page 79 Crankshaft axial play Caution:...

  • Page 31: Aligning An Engine With Flange−Mounted Gearbox

    Aligning an engine with flange−mounted gearbox Note: The mounts are pre−compressed at the factory by the shipping locks. For this reason it is not necessary to preload the resilient mounts before the alignment. Provisionally aligning drive line D Place the drive line and the resilient mounts onto the engine foundation using suitable crane lifting equipment.
  • Page 32 Aligning an engine with flange−mounted gearbox Aligning drive line The drive line (engine and gearbox) and the propeller shaft must be aligned so that the radial offset and angle offset of all the components are within the specified tolerances. Caution: In order to avoid damage by vibrations and oscillations, the alignment of the drive line must be checked annually or after approx.
  • Page 33 Aligning an engine with flange−mounted gearbox Checking gearbox output and propeller shaft for radial and angle offset Radial offset means that the centre lines of 2 associated flanges are actually parallel, but are offset laterally in relation to each other. À...

  • Page 34: Transmission Of Power By Propshafts

    Transmission of power by propshafts Drive line consisting of engine, highly resilient coupling, propeller shaft and gearbox Drive line consisting of engine, resilient coupling with flange bearing, propeller shaft and gearbox...
  • Page 35 This can be carried out by MAN for a fee. The requisite data are to be collected during the project phase in the form of a questionnaire − "Questionnaire on torsional vibration calculation for ship’s drive line".
  • Page 36 Transmission of power by propshafts Flywheels Note: To carry out an exact installation inspection, request an installation drawing showing detailed dimensions for the flywheel or flywheel housing. À Flywheel with I = 1.1 kgm for the installation of a highly resilient coupling Á...
  • Page 37 Transmission of power by propshafts The working angle of a propeller shaft The working angle ß of a propeller shaft is the angle between the propeller shaft and the input / output shaft. Basic guidelines for installing propeller shafts When a single cardan joint, universal joint or ball joint is rotated while bent, an irregular motion occurs at the output end.
  • Page 38 Transmission of power by propshafts Aligning engine and gearbox Alignment type Permitted tolerances Max. angle per joint See page 34 Input and output angles ß ß Difference jß ß j  0.5° 1 − (=working angles) must be the same Engine, propeller shaft and gearbox <1 % must be arranged in a line in the...
  • Page 39 Transmission of power by propshafts Installing propeller shafts When connecting the propeller shaft halves, make sure that the markings (arrows) on the splined shaft and the splined hub face each other. Caution: Incorrectly assembled propeller shafts will not compensate for irregular motions, but rather increase it.

  • Page 40: Combustion Air System And Charging

    Combustion air system and charging Diagram of the charging À Air filter à Turbocharger, low compression stage Á Turbocharger, high compression stage Ä Boost pressure control valve  Intercooler Å Charge air cooler The diagram shows the combustion air ducting on the V8−1200. The design is identical for V12−1800. There are two stages of turbocharging whereby the combustion air is cooled after each stage.
  • Page 41 Combustion air system and charging Combustion air requirement In order to burn fuel completely and thereby achieve full power, the engine requires an adequate supply of fresh air, the volume of which can be determined from the technical data provided in the appendix to this manual.

  • Page 42: Exhaust System

    Caution: If sea water ingresses the engine, it will result in a total write−off that is not covered by the MAN warranty. It is not permissible to provide a single common exhaust system for several engines. In the case if multi−engine layouts a separate exhaust system for...
  • Page 43 Exhaust system Exhaust gas outlet on the engine On both the V8−1200 and V12−1800 both banks of cylinders are routed to a central exhaust gas outlet. On both types, exhaust gas manifolds can be provided either for an exhaust gas outlet to the rear À...
  • Page 44 Exhaust system Injection of sea water into exhaust system After emerging from the heat exchanger, sea water is injected into the exhaust pipe and mixed with the exhaust gas. Schematic drawing of sea water injection (example) À Sea water Á Exhaust gas Â...
  • Page 45 Exhaust system Exhaust silencing Exhaust silencing can be achieved either by means of an exhaust outlet below the water line or by installing exhaust silencers. Exhaust outlet below water line As well as noise damping, an exhaust outlet below the water line normally gives rise to an increase in exhaust backpressure.
  • Page 46 Exhaust system Insulation of the exhaust pipe (applies for both wet and dry exhaust systems) Exhaust pipes must be carefully insulated using fireproof material. Danger: Missing or unsuitable insulation can lead D Accidents with burns D Fires in the engine room D High engine room temperatures Hot, non−insulated exhaust pipes heat up the engine room considerably.

  • Page 47: Cooling System

    The cooling system on all MAN engines is designed for seawater temperatures of up to 32°C (305 K). À Expansion reservoir Á...
  • Page 48 Cooling system Seawater inlet Sea water enters through a scoop À on the underside of the hull. In this way, the pressure created at the sea water inlet while the ship is moving can be utilised to supply the pump with sea water. Scoop Although the inlet cross−section of the scoop is determined by the diameter of the sea water inlet...
  • Page 49 Cooling system Seawater supply components Sea valve Ball valves which are bolted directly to the scoop should be used as sea valves À. These can be swiftly closed in an emergency (pipe break). In addition, the "Open / Closed" setting of the valve can be immediately identified from the position of the handle.
  • Page 50 Cooling system Seawater pump Flow rate of the seawater pump Á: Engine Flow rate Pressure Pressure model Litre / min down−- upstream stream of of pump pump V8−1200 −0.1 V12−1800 −0.1 Seawater inlet The seawater filter line is connected to the intake connection Á...
  • Page 51 Cooling system Choice of materials for pipework Various metals may not be freely combined with each other. If noble" and "non−noble" metals are combined, the non−noble" metal will corrode both of them due to bimetallic corrosion. This process is accelerated still further in humid or even salty atmospheres. The more non−noble a metal is, the more negative its negatively charged.

  • Page 52: Fuel System

    à Fuel supply from fuel tank to engine  Fuel supply Ä Fuel prefilter with water separator (MAN scope of delivery) Å Fuel tank Æ Fuel return from engine to fuel tank The fuel flows from the tank through the fuel prefilter with water separator Ä to the fuel system on the engine À.
  • Page 53 The smallest particles of dirt in the fuel system can lead to total failure of the injection system. The fuel pre−filter supplied by MAN must not under any circumstances be replaced by a different make. For CR engines, a fuel pre−filter with water separator is supplied loose (Manufacturer: MANN&HUMMEL).
  • Page 54 M10, respectively with washers DIN 125−10.5. Additional fuel pre−filter You may install a Racor filter Á upstream of the fuel filter delivered by MAN À. Note: The figures show a single filter. The installation for the reversible double filter is...
  • Page 55 Fuel system Fuel lines Fuel lines from tank to engine Fuel hoses À and Á are used to connect the engine fuel system with that of the ship side. Fuel supply connection À: Threaded connector ....M30x2 Note: The inside diameter (DN) of the fuel intake...

  • Page 56: Propeller System

    Propeller system Propeller suitability with reference to ship resistance and driving power Propulsion engine, ship’s hull and the propeller form a system, whose individual components interact. The propulsion engine provides the driving power, the ship’s hull accepts the driving power and the propeller transmits this driving power.
  • Page 57 Propeller system Power consumption of propeller too great The power consumption of the propeller is greater than the maximum power of the engine. The engine can therefore not reach its nominal speed (operating point Ã). À Engine power curve Á Propulsion resistance curve Â...
  • Page 58 Propeller system Load indication on MAN Monitoring Diagnosis System (MMDS) display The relative engine load can be shown on the Monitoring and Diagnosis System display as a %. The term "load" describes the torque of an engine that is required at a certain rpm.
  • Page 59 Propeller system Interpreting load indication The reading of the load display can be clarified by the following example, selected at random. Example 1: The load indicator shows 37% at a speed of 1720 rpm (75% of rated rpm). This means: Because the propeller is only accepting 37% of the maximum possible power at a speed of 1720 rpm, the engine cannot output more power.

  • Page 60: Auxiliary Power Take−Off

    Auxiliary power take−off Auxiliary power take−off for the drive of a hydraulic pump The V-engines can be equipped with an auxiliary power take−off (PTO) on the flywheel housing at the back of the engine on the right−hand side. A hydraulic pump À can be installed at this point. If no hydraulic pump is provided ex−works, then the auxiliary power take−off is closed off with a blind flange Á.

  • Page 61: Electrical System

    Each engine has a separate battery for the starter. 24V DC consumers are to be supplied by their own batteries. Starters All MAN ship engines have starters with 2 poles. For this reason the positive cable of the starter battery connects to terminal 30 of the starter À, the negative cable of the starter...
  • Page 62 Electrical system Battery size and starter cable Starters Mitsubishi 105P70 Battery capacity Battery current as per DIN 43539 Battery current as per DIN EN 50342 A 1050 1150 Battery resistance at 20°C mΩ Permitted battery cable resistance (positive max. max. max.
  • Page 63 Electrical system Generators The starter battery of each engine is charged by a generator À. The generator has been completely wired at the factory. This generator may not be used to charge other batteries used to power other consumers. A second generator Á (optional) can be installed to charge those batteries used to power other consumers.
  • Page 64 Electrical system Terminal box The terminal boxes are connected to the ship ground using ground cables À. Engine and gearbox mounts The engine and gearbox must be connected to the ship ground by a ground cable. Remove paint from a small area to provide a good contact with the ground cable.

  • Page 65: Electrical Preheating Of Coolant

    Electrical preheating of coolant If required, the engines can be equipped with an electrical coolant preheating system. Purpose and function of coolant preheating Coolant preheating is designed to facilitate starting the engine when external temperatures are low and to ensure the availability of the full power output immediately after a cold start (warm−up phase not required). For this purpose, the coolant is preheated with the engine at a standstill.

  • Page 66: Cabin Heater

    Cabin heater Basic setup The control stand and the ship’s quarters can be heated with a part of the heat generated by the engine in the coolant. For this purpose part of the coolant is bypassed through a heat exchanger. The heat generated there can be used to heat the cabins.
  • Page 67 Cabin heater Connection of cabin heater If required, the engines can be equipped at the factory with a connection for the cabin heater. Feed line À Ball valve Á Union nut for threaded connection M26x1.5 Return line  Ball valve Ã...

  • Page 68: Throttle Lever Control System

    Bosch Rexroth throttle lever control system Components of the remote control A Marex MPC OSII (MPC) system consists of at least one throttle lever Á and one MPC controller unit Â, which are located in the upper section of the MAN engine terminal box.
  • Page 69 S1 S2 S1−ON S1−ON S1−ON S1−ON S2−ON S2−ON S2−ON S2−ON MAN terminal box MAN terminal box MAN terminal box MAN terminal box MAN terminal box MAN terminal box Cross communication S1: CAN bus throttle lever terminator S2: Cross communication terminator...
  • Page 70 To preclude confusing with other CAN bus cables, please note the metal guide À of the union nut and the green marking Á at the cable ends. CAN bus connection lines and termination resistors MAN Part Number Bosch Rexroth number Designation 51.25449−0056...
  • Page 71 Throttle lever control system Terminating resistor at throttle lever control The Bosch Rexroth throttle lever for the Marex OSII (MPC) controller communicates with the controller in the engine room through the CAN bus. This CAN bus must always be fitted with terminating resistors at both ends (start and finish ends).
  • Page 72 Throttle lever control system Terminating resistor for cross communication In multi−engine applications the Marex OSII (MPC) controller in the engine room requires a connection (cross communication) to the other engines. This cross communication is also made using a CAN bus and serves as a data exchange e.g.
  • Page 73 Throttle lever control system Solenoid valve plug (Item no. 51.25432−0070) The components À integrated into connector Á serve to protect the control electronics of the terminal box and to signal the gear status (LED) of the gearbox. A considerable advantage in this case is the protection against polarity reversal of the tens diode and the LED.

  • Page 74: First Commissioning − Lube Oil System

    V8−1200, V12−1800 engines may only be operated with oils complying with works standard M 3277. Note: Only use fuels, lubricants and coolants in accordance with MAN regulations, otherwise the manufacturer’s warranty will not apply! For basic information on consumables, refer to the publication Fuels, Lubricants and Coolants for MAN Diesel Engines".

  • Page 75: First Commissioning − Cooling System

    First commissioning − Cooling system Filling and venting the cooling system Danger: There is a risk of burns and scalding. During filling, the cooling system is to be vented by means of the threaded vent plugs  on the liquid−- cooled exhaust turbochargers and on the exhaust manifold.
  • Page 76 First commissioning − Cooling system Case 2: Engine mounted horizontally (The threaded vent plugs  are located above the coolant level in the expansion tank À) In this case complete filling and venting of the cooling system is only possible, if the cooling system is filled via the drain / filler valve Ã...
  • Page 77 First commissioning − Cooling system Danger: If in an exceptional case the coolant level has to be checked with the engine still hot from operation, first carefully loosen the locking cap − relieve the pressure − then open carefully. If the cooling system is opened with the engine hot from operation, this will cause a loss of pressure in the cooling system.
  • Page 78 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 79: Appendix

    Appendix...

  • Page 81: Tightening Torques For Bolted Connections

    Tightening torques for bolted connections Tightening torques for bolted connections as per factory norm M 3059 Bolts / nuts with external hex−head or hex socket head, or head without collar or flange Thread size Strength classifications / tightening torque in Nm x pitch at 8.8 / 8 at 10.9 / 10...
  • Page 82 50 l 60 l Oil change quantity (with filter) 62 l Lube−oil pressure Monitored by MAN Monitoring and Diagnosis System (MMDS) Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling Liquid cooling Coolant temperature 80−90°C, 95°C permissible temporarily...

  • Page 83: Technical Data

    Technical data Power and combustion data Rated power 882 KW / 1200 HP Rated speed 2300 rpm Effective mean pressure 28.5 bar Fuel consumption at full load 225 g/kWh and rated speed Combustion air requirement 4100 m Exhaust mass flow rate 4515 kg/h Exhaust temperature 500°C...
  • Page 84 70 l 90 l Oil change quantity (with filter) 92 l Lube−oil pressure Monitored by MAN Monitoring and Diagnosis System (MMDS) Oil filter 2 oil modules, each with 2 oil coolers and an oil separator Engine cooling Liquid cooling Coolant temperature 80−90°C, 95°C permissible temporarily...
  • Page 85 Technical data Power and combustion data Rated power 1324 KW / 1800 HP Rated speed 2300 rpm Effective mean pressure 28.5 bar Fuel consumption at full load 215 g/kWh and rated speed Combustion air requirement 6300 m Exhaust mass flow rate 7600 kg/h Exhaust temperature 500°C...
  • Page 86 14 Cross communication MPC − CAN−bus (X13) 51.25449−0056 (2 m); 51.25449−0057 (5 m); 51.25449−0057 (10 m); 51.25449−0057 (15 m); 15 Gearbox controller line, trolling (X8) 16 Diagnosis connection MAN−Cats, diagnosis software MMDS, reprogramming EDC7 (X10) 17 Start−Stop panel (EOP), (X7) 18 Ground connection...

  • Page 87: Mmds Can−Bus (V8−1200, V12−1800)

    MMDS CAN−Bus (V8−1200, V12−1800) 17 16...

  • Page 88: Potential Free Wiring Diagram Of Basic Components

    Potential free wiring diagram of basic components Port engine Starboard engine Starter Starter Batteries Batteries motor motor for starter for starter motor motor 1st. Alternator 1st. Alternator Batteries Batteries for additional 2nd. Alternator for additional 2nd. Alternator onboard (optional) onboard (optional) consumers consumers...

  • Page 89: Index

    Index Air filters, Vacuum downstream of air filter ..Exhaust back pressure Air intake system, combustion air ... . Max. perm......Aligning the drive line .
  • Page 90 Index Safety regulations ..... . . 3 − 9 Technical data Handling used engine oil ....V12 −...

This manual is also suitable for:

V12-1800

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