Man D 2840 LE 403 Operating Instructions Manual
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Man D 2840 LE 403 Operating Instructions Manual

Marine diesel engines
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Summary of Contents for Man D 2840 LE 403

  • Page 3 Operating Instructions – MAN Marine Diesel Engines...
  • Page 5 It is imperative and in your own interest to entrust your MAN Local Service Centre with the removal of any disturbances and with the performance of checking, setting, and repair work.
  • Page 6 Flat seals / gaskets can be fitted properly only if the following points are ob- served: D Use only genuine MAN seals / gaskets D The sealing faces must be undamaged and clean D Do not use any sealing agent or adhesive – as an aid to fitting the seals a little grease...

  • Page 7: Table Of Contents

    Contents Page Declaration ............. . . Nameplates .

  • Page 8: Declaration

    In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of Directive 89/392/EEC, version 93/44/EEC MAN Nutzfahrzeuge Aktiengesellschaft, hereby declares that the engine described below is destined for installation in a machine as defined in the EC directive on machines.

  • Page 9: Nameplates

    The engine type plates are on the crank- case (see illustration). Model MAN Nutzfahrzeuge Aktiengesellschaft ..............Motor-Nr. / Engine No. delivered on NI/II ..............

  • Page 10: Safety Regulations

    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. D Keep vicinity of engine, ladders and stairways free of oil and grease.
  • Page 11 Safety regulations During maintenance and care D Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scald- ing.
  • Page 12 If faults occur, find the cause immediately and have it eliminated in order to prevent more serious damage. Use only genuine MAN spare parts. MAN will accept no responsibility for damage result- ing from the installation of other parts which are supposedly “just as good”.
  • Page 13 Safety regulations 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. D Filter elements are classed as dangerous waste and must be treated as such. Coolant D Treat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.

  • Page 14: Commissioning And Operation

    Commissioning and operation Engine views D 2840 LE 403 17 16...
  • Page 15 Commissioning and operation 1 Heat exchanger and coolant surge tank 2 Relief valve on coolant surge tank 3 Intercooler 4 Coolant filler neck 5 Oil filler neck 6 Oil separator valve for crankcase breather 7 Air intake 8 Turbocharger 9 Exhaust pipe 10 Oil dipstick 11 Starter motor 12 Oil sump...

  • Page 16: First Commissioning

    When putting a new or overhauled engine into operation for the first time pay attention to the “Installation instructions for MAN marine diesel engines” without fail. It is recommended that new or overhauled engines should not be operated at a load higher than about 75% maximum load during the first few hours of operation.
  • Page 17 Commissioning and operation Raw water pump Do not let raw water pump run dry. Make sure that all valves / cocks in the raw water circuit are open. If there is a risk of frost, drain the raw wa- ter pump. Filling with engine oil Caution: Do not add so much engine oil...

  • Page 18: Commissioning

    Commissioning and operation Commissioning Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if necessary. Note: Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the manufacturer’s warranty will become null and void. Checking oil level Check engine oil level only approx.

  • Page 19: Starting

    Commissioning and operation Starting Danger: Before starting make sure that no-one is in the engine’s danger area. Caution: When starting do not use any additional starting aids (e.g. injection with starting pilot). Ensure that the gearbox is in neutral. Insert starter key and turn it to position “I”. The check lamp comes on to show that the engine is ready for operation.

  • Page 20: Operation Monitoring

    Commissioning and operation Operation monitoring The D 2840 LE 403 / D 2842 LE 404 is equipped as series standard with a monitoring and diagnostic system MMDS. On the control console and alternatively on other control stands, the following display de- vices are available for monitoring operation: 1.
  • Page 21 Commissioning and operation 2. Display device MMDS-L The engine monitoring alarms the officer MAN MARINE DIESEL guiding the ship when important engine operating values are outside the permitted Boost pressure Engine in operation tolerance range. Generator/speed sensor Coolant level Engine oil pressure Overspeed Engine coolant temp.
  • Page 22 Commissioning and operation Operation of the display device MMDS-L The display device has the following operating keys: Switches off the alarm horn and the integrated buzzer Switches off the flashing signal of the relevant warning lamp, i.e. the flashing light switches to continuous light.
  • Page 23 Commissioning and operation 3. Display device MMDS-LC The device serves to visualise analog en- MAN MARINE DIESEL gine data, as well as visual and acoustic notification of engine alarms. All engine data is entered at the factory in the lan-...
  • Page 24 Commissioning and operation 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.
  • Page 25 Commissioning and operation If an alarm is activated, the device switches automatically to the alarm screen. Each new entry is made in the top line. Any messages that might already be present shift one line 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.
  • Page 26 Commissioning and operation When the acoustic acknowledgement (Horn Quit key) has been pressed, the integrated buzzer switches off. With the visual acknowledgement (Visual Quit key), the flashing text and the LED “Alarm” switches to continuous display. When the fault has been remedied, the alarm text disappears from the monitor.
  • Page 27 Commissioning and operation Visual Quit / Test: Standard function: visual acknowledgement, i.e. all flashing alarm texts in the currently visible alarm screen switch to constant represen- T E S T tation if the horn was acknowledged beforehand; the red alarm LED integrated in the front plate is also switched from flashing to continu- ous lighting.
  • Page 28 Commissioning and operation ALARMS: Standard function: Calling up the alarm screen; the five alarms or warnings last issued and still present are displayed. At the top left of ALARMS the monitor is the code A1. If there are more than 5 messages issued, the messages can be displayed in groups of five by pressing the key M en again.
  • Page 29 Commissioning and operation T E S T R E S ET The selection cursor can be moved using the Move function (+– keys The Enter function (PRG key ) is used to accept each marked language and high- P rg light it in black.
  • Page 30 Commissioning and operation The function is called up using the PRG key P rg A new page is opened and the current time (time / date) is displayed. The selection cursor jumps to “Hour”. set-time hour minute second time (H:M:S) >13<...
  • Page 31 In the event of an alarm, the corresponding measurement point text appears on the alarm page; the program switches automatically into the alarm menu. In the case of warnings, the program does not switch automatically into the alarm menu. 4. Engine room panel MMDS-EP MAN MARINE DIESEL Motordrehzahl 1835 upm Motoroeldruck 4.3 bar...
  • Page 32 Commissioning and operation 5. Drive lever control system Mini Marex At the request of the shipyard or customer, it is possible to purchase from MAN an elec- tronic drive lever control system made by Mannesmann Rexroth, type Mini Marex. This control system has plug connections specially configured for MAN.
  • Page 33 Commissioning and operation “Gearbox forwards / reverse” (lock) position Á In this lever position, two different functions are possible. 1. Standard function: The gearbox clutch is engaged to “Forwards” or “Reverse”; the power unit is idling. 2. “Increase engine speed” function: The “Increase engine speed”...
  • Page 34 Commissioning and operation Additional function “Warming Up” The expression “Warming Up” means “engine running without shifting gear”, which en- ables, for example, warm-up of a cold power unit across the entire speed range. The gearbox clutch is not engaged in lever position Á. Starting the “Warming Up”...
  • Page 35 Commissioning and operation Additional function: switch error message to mute The acoustic signal transmitter, which is activated for some alarms, can be disabled at the relevant control stand by pressing the “Command takeover” key. . However, this does not delete the alarm! Display Alarm L7 and L8 This display element is present on the command master twice (once for the port system / once for the starboard system).
  • Page 36 Commissioning and operation Pressing the “Syn./Trol.” key (press once) enables the “Engine speed synchro- nisation” function. Pressing the key again (press once) disables the function once again. SYN/TROL It is only possible to enable or disable the engine speed synchronisation on the active control stand when both command master levers are in the engine speed range “Forwards”...
  • Page 37 Commissioning and operation Neutral (lock) Gear: forwards Gear: reverse Clutch: 100% slip Clutch: 100% slip (lock) (lock) Infinitely variable Infinitely variable slip adjustment and slip adjustment and speed increase speed increase Reverse area Forwards area Operating field Clutch: 0% slip (grip) Clutch: 0% slip (grip) and max.
  • Page 38 Commissioning and operation Acoustic signal transmitter The acoustic signal transmitter is located below the command master and is present once on each system (once for the port system and once for the star- board system). The signal transmitter supports the visual displays of the command master light- ing and the alarm lamp with acoustic signals.
  • Page 39 Commissioning and operation 2. Command request: The command can be requested at any control stand. The control levers of the command master on the requesting control stand must be set at the “Neutral position”. . “Command master calibration and enable of control stands” must have been carried out.
  • Page 40 Commissioning and operation 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 comparison or free command change. On twin-engine systems, both setting units must have the same setting.
  • Page 41 Commissioning and operation 2nd step: Command takeover on the selected control stand. Execution: – Press “Command” key once to take over 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.
  • Page 42 6. Emergency operation unit: The emergency operation control system – Em – is conceived as a simple engine MAN MARINE DIESEL speed and gearbox control system which enables safe continuation of a trip in the event of a failure in the electrical control Em.Op...
  • Page 43 Commissioning and operation Operating the emergency operation unit Requirements for operation / activation / deactivation: D Operation of the emergency operation control system is only permitted in neutral posi- tion of the command master of the control lever system D The emergency operation control system should only be activated when the engine is running.
  • Page 44 Commissioning and operation Gearbox control With emergency operation active, the gearbox is controlled using 3 key functions in the positions Neutral, Forwards or Reverse: Shift gearbox to neutral position Shift gearbox to forwards position Shift gearbox to reverse position Gearbox shifting only takes place when the engine speed is in the idle range. It is advisable always to switch the gearbox into neutral first prior to reversing.
  • Page 45 Commissioning and operation Disabling emergency operation Emergency operation is always terminated automatically when the engine is switched off; the ignition must be switched off for at least 3 seconds. After switching on again, normal control lever operation is enabled first, i.e. the emerg- ency operation system must be reactivated if required.
  • Page 46 Commissioning and operation Main fuses for + / – on the engine Two main fuses with 20 A are fitted at the engine; these blow in the event of overcurrent or short circuit. If a fuse as blown, the engine can no longer be started. The fuses can be reset by the operator using the keys fitted.
  • Page 47 Commissioning and operation Main fuses on terminal box Three more main fuses are fitted in the terminal box. These fuses blow in the event of overcur- rent or short circuit. They separately protect D the electronic fuel injection EDC, F5=16 A D the diagnosis system, F6=10 A D and the external electrical connections, F7=10 A...
  • Page 48 Commissioning and operation Terminal box in the engine room / interface with light-emitting diodes + keys MAN Marine Diesel RESET TEST Serial data activity TYP BE3 The terminal box with light-emitting diodes functions at the same time as an engine room monitoring panel.

  • Page 49: Shutting Down

    Commissioning and operation – In the case of an engine slow down alarm, short-term lowering of engine speed below 800 rpm so that higher engine speed can be reached – In the case of a stop alarm, the alarm can only be deleted if the engine is at a standstill The following light-emitting diodes function continuously: D Power on:...

  • Page 50: Maintenance And Care

    Maintenance and care Lubrication system Ensure outmost cleanliness when handling fuels, lubricants and coolants. Note: Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the manufacturer’s warranty will become null and void. Engine oil change Danger: The oil is hot- risk of scalding. Do not touch the oil drain plug with bare fingers.
  • Page 51 Maintenance and care Refilling with oil Caution: Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Overfilling will result in damage to the engine. Refill with fresh engine oil at the oil filler neck (arrow).
  • Page 52 Maintenance and care During continuous operation position the Continuous operation selector lever that both filter halves are in (both filter halves operation. in operation) Observe positions of selector lever! Right-hand filter Caution: cut out Do not leave selector lever in any intermediate position because this Left-hand filter would be liable to interfere with oil...

  • Page 53: Fuel System

    Maintenance and care Fuel system Fuel If Diesel fuel which contains moisture is used the injection system and the cylinder liners / pistons will be damaged. This can be prevented to same extent by filling the tank as soon as the engine is switched off while the fuel tank is still warm (formation of con- densation is prevented).
  • Page 54 Maintenance and care Parallel fuel filter Changing fuel filter Only when engine is switched off D Loosen filter cartridge by means of tape wrench, unscrew it by hand and take it D Moisten the seals on the new filter car- tridge with fuel D Screw on the filter cartridges and tighten them vigorously by hand...
  • Page 55 Maintenance and care Changing fuel filter D Loosen filter cartridge by means of tape wrench, unscrew it by hand and take it D Moisten the seals on the new filter car- tridge with fuel D Screw on the filter cartridges and tighten them vigorously by hand D Bleed fuel system D Check filter for leaks...

  • Page 56: Cooling System

    Maintenance and care Cooling system Danger: Draining hot coolant involves a risk of scalding. Draining the cooling system Caution: Drain coolant into a suitable con- tainer and dispose of it in accor- dance with regulations. Drain coolant as follows, but only when the engine has cooled down: D Briefly open cap À...
  • Page 57 Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze agent on ethylene glycole basis or anti-corrosion agent. See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”. Coolant must be added at the filler neck only À...
  • Page 58 Maintenance and care D Before the engine is next put into operation (with the engine cold) check the coolant level and top up if necessary D Repeat this procedure 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...

  • Page 59: V-Belts

    Maintenance and care V-belts Checking condition D Check V-belts for cracks, oil, overheat- ing and wear D Change demaged V-belts Checking tension Use V-belt tension tester to check V-belt tension. D Lower indicator arm À into the scale D Apply tester to belt at a point midway between two pulleys so that edge of contact surface Á...
  • Page 60 Maintenance and care Tensioning and changing V-belt Alternator 120A D Remove mounting nut À D Turn setting screw Á in clockwise direc- tion until the tension of the V-belts is correct. D Retighten mounting nut. To change the V-belts turn the setting screw anti-clockwise 55 A alternator on heat exchanger D Remove fixing bolts À...

  • Page 61: Alternator

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

  • Page 62: Technical Data

    Technical data Model D 2840 LE 403 Design V 90° Cycle 4-stroke Diesel with turbocharging / intercooling and wastegate Combustion system Direct injection Turbocharging Turbocharger with intercooling and wastegate Number of cylinders Bore 128 mm Stroke 142 mm Swept volume...
  • Page 63 Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. shallow 32 l 38 l deep (front end sump) 26 l 30 l deep (V48) 38 l 48 l Oil change quantity (with filter) shallow 41 l deep (front end sump) 33 l deep (V48)
  • Page 64 Technical data Model D 2842 LE 404/407/410/414/415/416/417 Design V 90° Cycle 4-stroke Diesel with turbocharging / intercooling and wastegate Combustion system Direct injection Turbocharging Turbocharger with intercooling and wastegate Number of cylinders Bore 128 mm Stroke 142 mm Swept volume 21 930 cm Compression ratio 13.5 : 1...
  • Page 65 Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. deep 24 l 32 l deep (V70) 60 l 70 l semi-shallow 22 l 30 l for 38 / 45° tilt 37 l 45 l Oil change quantity (with filter) deep 35 l deep (V70)

  • Page 66: Troubleshooting Table

    Troubleshooting table Fault Engine does not start, or starts only with difficulty Engine starts but does not reach full speed or stalls Engine idles out of true when warm, misfiring Engine speed fluctuates during operation Power output unsatisfactory Coolant temperature too high, coolant being lost Lube oil pressure too low Lube oil pressure too high Black smoke accompanied by loss of power...
  • Page 67 Troubleshooting table Fault Engine does not start, or starts only with difficulty Engine starts but does not reach full speed or stalls Engine idles out of true when warm, misfiring Engine speed fluctuates during operation Power output unsatisfactory Coolant temperature too high, coolant being lost Lube oil pressure too low Lube oil pressure too high Black smoke accompanied by loss of power...

  • Page 68: Index

    Index Alternator ....... . Nameplates ....... Bleeding the fuel system .

This manual is also suitable for:

D 2842 le 410D 2842 le 414D 2842 le 415D 2842 le 416D 2842 le 417D 2842 le 404 ... Show all

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