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Table of Contents
Related Manuals for Man V8-1000
Summary of Contents for Man V8-1000
- Page 3 Installation and Operating 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...
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Page 4: Printer's Imprint
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. -
Page 5: Table Of Contents
MAN marine diesel engines D2868 LE.. / D2862 LE4.. Contents Printer's imprint ............... . . - Page 6 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Contents Design and function ............. . .
- Page 7 MAN marine diesel engines D2868 LE.. / D2862 LE4.. Contents Control and operation .............
- Page 8 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Contents Decommissioning and recommissioning ..........
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Page 9: Foreword
Only use genuine MAN spare parts and accessories or spare parts and accessories 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. -
Page 10: Explanation Of Symbols
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Foreword 1.2 Explanation of symbols Warnings Warnings in these instructions are indicated by symbols. The instructions are preceded by signal words that indicate the extent of the danger. Always follow the instructions and proceed cautiously to prevent accidents, injury and damage. -
Page 11: Limitation Of Liability
The obligations 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. -
Page 12: Spare Parts
Only use genuine MAN spare parts and accessories or spare parts and accessories 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. -
Page 13: Warranty Conditions
Foreword 1.9 Warranty conditions The obligations 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. Failure to adhere to these instructions and all accompanying supplier operating instructions will lead to the loss of claims under the warranty. - Page 14 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Foreword Diese Anleitung vor Beginn aller Arbeiten sorgfältig durchlesen! Dies gilt insbesondere für das Kapitel Allgemeine Sicherheitshinweise und die jeweiligen Sicherheitshinweise in den Kapiteln.
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Page 15: General Safety Instructions
The engine is designed and built exclusively to power marine vessels. Any use other than this is deemed non-intended use. MAN accepts no liability for damage resulting from non-intended use. In this case, the risk is borne entirely by the operator. -
Page 16: Content Of The Installation And Operating Instructions
MAN. If any changes are made without the written approval of MAN, MAN shall not be liable for any warranty or warranty claims arising from damage and defects attributable to the unauthorised modification. Further... -
Page 17: Personnel Requirements
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 2.5 Personnel requirements 2.5.1 Qualifications WARNING Risk of injury due to lack of qualifications Incorrect actions can lead to serious injury or damage. Therefore: S Always have specific work performed by the appointed personnel as per the relevant sections in these instructions. -
Page 18: Personal Protective Equipment
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 2.6 Personal protective equipment Personal protective equipment must be worn during work to minimise health risks. S Always wear the personal protective equipment required for the particular work whilst performing this work. -
Page 19: Specific Dangers
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 2.7 Specific dangers Determined residual risks are described in the following section. S Follow the safety instructions included here and the warning instructions in the other sections of these operating instructions to reduce health risks and avoid dangerous situations . - Page 20 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions Exhaust gases WARNING Health risk due to leaking exhaust system Exhaust gases pose a health risk. Therefore: S Immediately stop and repair machines with leaking exhaust systems. S Ensure sufficient ventilation.
- Page 21 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions Hot Surfaces CAUTION Risk of burns due to hot surfaces Contact with hot parts causes burns. Therefore: S Always wear protective workwear and protective gloves when working near hot parts.
- Page 22 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions Work on the common-rail system WARNING Risk of injury due to discharging fluids Fluids discharged under high pressure (1800 bar) can cause serious injuries. Therefore: S Always have work on the common-rail system performed by trained, qualified personnel.
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Page 23: Safetyequipment
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 2.8 Safetyequipment The operator must have the following safety equipment in place: Install emergency off device and include in the plant's safety system before operating the engine. Connect the emergency off device so as to prevent dangerous situations for people and property if the en... -
Page 24: Procedure In The Event Of Danger Or Accidents
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 2.10 Procedure in the event of danger or accidents Preventive measures S Always be prepared for accidents or fire! S Keep first-aid equipment (first-aid kit, blankets etc.) and fire extinguishers close to hand. -
Page 25: Signs And Notices
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 2.11 Signs and notices The following symbols should be attached in the immediate danger zone. WARNING Risk of injury due to illegible symbols Signs, notices and symbols get dirty over time or become illegible in some other way. -
Page 26: Weight Data
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 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 Crankshaft Flywheel... -
Page 27: Environmental Protection
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 2.13 Environmental protection ENVIRONMENTAL NOTE Risk of environmental pollution due to incorrect handling of fuels, lubricants and coolants This can severely damage the environment. Therefore: S Follow the safety instructions. - Page 28 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. General Safety Instructions 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.
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Page 29: Engine Model Plate
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Engine Model Plate 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. -
Page 30: Explanation Of Motor-Nr./Engine-No. (Engine Identification Number)
3.3 Data on the engine model plate Please always quote the engine model, engine number and order number when corresponding with MAN. You should therefore check the relevant data on the engine model plates and enter it on page 27 before commissioning of the engine. -
Page 31: Design And Function
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Design and Function Design and function 4.1 Engine application fields The D2868 LE4.. (V8) and D2862 LE4.. (V12) marine engines are suitable for powering marine vessels for light-duty applications. Correlation of the engine types to the approved modes of operation, see "Technical Data" on page 106. - Page 32 MAN marine diesel engines D2868 LE.. / D2862 LE4.. Design and Function Flywheel 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.
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Page 33: Engine Views
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Design and Function 4.3 Engine views 4.3.1 Front left view The picture shows an D2862 LE4.. engine with 1-stage turbocharching (example). Exhaust manifold Oil dip stick EDC-Box V-belt guard Oil filler neck... -
Page 34: Rear Right View
MAN marine diesel engines D2868 LE.. / D2862 LE4.. Design and Function 4.3.2 Rear right view The picture shows an D2862 LE4.. engine with 1-stage turbocharching (example). Exhaust pipe, liquid cooled Flywheel Fuel pre-filter with hand priming pump Sea water pump... -
Page 35: Transport, Packaging And Storage
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage Transport, packaging and storage Always read the installation instructions when installing and commissioning a new or overhauled engine. User tip Installation and commissioning is performed solely by the employees of the plant manufacturer or per... - Page 36 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage Off-Centre Point of Gravity WARNING Danger to life due to incorrect handling of package Package swings out, tilts and/or falls. Therefore: S Use the crane hook lugs solely for transporting the engine without mounted components (without alternator).
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Page 37: Transport Inspection
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage 5.3 Transport inspection Check 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. -
Page 38: Transport
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage 5.4 Transport 5.4.1 Engine without gearbox Lifting Points For lifting the engine, 4 crane hook lugs are mounted on the engine. Use sufficiently dimensioned crane lifting gear... -
Page 39: Engine With Gearbox
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage 5.4.2 Engine with gearbox Lifting Points For lifting the engine with gearbox, there are 2 crane hook lugs mounted on the gearbox and 2 crane hook lugs mounted on the engine... - Page 40 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage WARNING Danger to life due to incorrect handling of package Package swings out, tilts and/or falls. Therefore: S Use the crane hooks solely for transporting the engine with gearbox.
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Page 41: Packaging
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage 5.5 Packaging Packaging The individual packages are packed in accordance with the expected conditions of transport. The purpose of the packaging is to protect the components from transport damage, corrosion and other damage. - Page 42 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Transport, Packaging and Storage 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.
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Page 43: Installation And Commissioning
S Safety gloves 6.1.2 Safety instructions Personnel 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... -
Page 44: Engine Installation
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.2 Engine installation 6.2.1 Interfaces between engine and plant Exhaust system Sea water outlet Intake system Engine cooling system Engine mounts Intercooling system The following assembly work must be performed at the interfaces between engine and plant when installing... - Page 45 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning Exhaust system Sea water inlet Fuel system Electrical system Auxiliary power take-off Lube oil system Flywheel The following assembly work must be performed at the interfaces between engine and plant when installing...
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Page 46: Installation Instructions
The installation drawing provides information on the type of connections and the 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. -
Page 47: Completion Of The Engine And Assembly Of The Equipment Set
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.3 Completion of the engine and assembly of the equipment set When installing the engine, ensure that there is enough space available for the regular maintenance work specified in the maintenance schedule. -
Page 48: Mounting A Gearbox On The Flywheel Housing
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.3.2 Mounting a gearbox on the flywheel housing Flywheel The connection dimensions for the flywheel indicated on the installation drawing. S Remove oil, grease and preservative from the flywheel. -
Page 49: Checking The Crankshaft Axial Clearance
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.3.3 Checking the crankshaft axial clearance NOTE The designed crankshaft axial clearance of the engines must not in any event be reduced by the install ation of couplings or other components. -
Page 50: Installation Of The Propulsion System In The Ship
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.4 Installation of the propulsion system in the ship 6.4.1 Installing the resilient engine and gearbox mounts Identification of the mounts The resilient mounts can be supplied by MAN. -
Page 51: Connecting The Cooling System
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.5 Connecting the cooling system 6.5.1 Connecting the sea water lines for engine cooling The installation drawing specifies the implementa tion of the coolant connections. S Connect coolant inlet... -
Page 52: Connecting The Fuel Lines
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.6 Connecting the fuel lines 6.6.1 Connecting the fuel lines S Connect the fuel feed S Connect the fuel return For hose connections, see installation drawing on page 113. -
Page 53: Securing The Fuel Pre-Filter
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.6.2 Securing the fuel pre-filter NOTE Risk of damage due to dirt particles Risk of component damage due to dirt in the fuel system Therefore: S Ensure complete cleanliness when working on the fuel system. -
Page 54: Exhaust System
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.7 Exhaust system 6.7.1 Exhaust gas outlet on the engine Both cylinder banks are combined in a central ex haust outlet. The exhaust manifold for the exhaust outlet can be... -
Page 55: Connection Between The Exhaust System And The Engine
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.7.2 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... -
Page 56: Starter Motor
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.7.3 Starter motor NOTE Component damage due to corrosion Therefore: S The negative cable of the starter battery is to be connected to starter terminal 31. S Connect the engine and all pipe connections from and to the engine with the ship's potential by means of "grounding cable". -
Page 57: Alternators
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.7.4 Alternators For charging the starter batteries, each engine has an alternator available. The alternator has been completely wired at the factory. This alternator may not be used to charge other batteries used to power other consumers. -
Page 58: Tightening Torques For Threaded Connections To Works Standard M 3059
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 6.8 Tightening torques for threaded connections to Works Standard M 3059 Bolts / nuts with external or internal hex, head without collar or flange Thread size Strength classifications / tightening torque in Nm x pitch at 8.8 / 8... -
Page 59: First Commissioning
Incorrectly performed first commissioning results in operating faults which lead to the engine becoming a total write-off. Therefore: S Commissioning is to be performed solely by personnel authorised by MAN Nuremberg (Marine Engi nes department). WARNING Danger to life due to non-functioning safety equipment... - Page 60 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation and commissioning 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.
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Page 61: Control And Operation
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation Control and operation 7.1 Prerequisite Wear personal protective equipment. The following protective equipment must be worn: S Protective 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. -
Page 62: Preparation For Operation
If necessary, top up diesel fuel, coolant and oil. 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. -
Page 63: Checking And Topping Up The Fuel Level
An incorrect mixture of antifreeze and corrosion inhibitor leads to failure of the cooling system. Therefore: S Prepare coolant as specified in the publication entitled "Fuels, lubricants and coolants for MAN indus trial and marine diesel engines". Checking the coolant level Only check the coolant level with the engine cooled down. - Page 64 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation Topping up the coolant Only top up the coolant with the engine cooled down. S If, under exceptional circumstances, the coolant level has to be checked with the en gine at operating temperature, carefully turn the to the first detent position - drain pres...
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Page 65: Checking The Engine Oil Level
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation 7.3.3 Checking the engine oil level NOTE Ensure that the engine's entire oil 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. -
Page 66: Topping Up The Engine Oil
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation 7.3.4 Topping up the engine oil NOTE Risk of damage due to incorrect oil quantity Engine damage Therefore: S Never add more than the specified oil quantity. S Ensure that the oil level is correct. -
Page 67: Check Water Separator Of Fuel Filters
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation 7.3.5 Check water separator of fuel filters In order to protect the engine from dirt and water in the fuel, a fuel prefilter with water separator is installed in the fuel line from the tank to the engine. -
Page 68: Daily Inspection Before Starting The Engine
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation 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... -
Page 69: Starting And Stopping The Engine
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation 7.4 Starting and stopping the engine The engine can be started and stopped by one of the following: An ignition lock A button (without ignition lock) Starting the engine The engine can be started and stopped in the en... -
Page 70: Running The Engine For Ship Operation
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation 7.5 Running the engine for ship operation 7.5.1 Operating ranges for marine engines Speed in % (1) Acceleration S Brief operation for increasing the 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"... -
Page 71: Display Systems And Instruments
7.5.2 Display systems and instruments Colour display MMDS-CLC 6.5 MAN can supply the MMDSCLC 6.5 colour display as an option. This device registers the engine and gearbox sensor data. Several graphic pages depict the recorded measured values in the form of digital displays and circular gauges. - Page 72 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation Visualisation of engine data on colour display MMDS-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.
- Page 73 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Operation Instrument 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...
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Page 74: Override System
Operation 7.5.3 Override system Following an alarm that can lead to engine damage, the MAN Monitoring Diagnostic System reduces the engine speed and, therefore, 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. -
Page 75: Maintenance And Care
S Make sure the working area is kept clean and orderly! 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. -
Page 76: Maintenance Schedule
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care ENVIRONMENTAL NOTE Coolant S Antifreeze and mixtures of antifreeze and water are to be handled as hazardous waste. When dispos ing of used coolant observe the regulations of the local authorities. -
Page 77: Maintenance Work
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 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. - Page 78 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care Draining the engine oil 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.
- Page 79 For this reason: S Only use approved fuels, lubricants and coolants (see the publication entitled "Fuels, Lubricants and Coolants for MAN Industrial and Marine Diesel engines"). A current list of approved products can be found on the internet at: www.asp.mantruckandbus.com...
- Page 80 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care Filling engine oil The engine oil pan can be filled via the filler neck on a valve cover and using the electric oil change pump. Fill the engine oil pan via the oil filler neck Prepare the specified maximum fill quantity for the oil pan mounted on the engine in a canister.
- Page 81 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care Check the engine oil level Perform oil level check. 1. Pull out the oil dipstick. 2. Wipe off the oil dipstick with a clean, lint-free cloth. 3. Re-insert the oil dipstick up to the stop.
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Page 82: Maintaining The Fuel Filter
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 8.4.2 Maintaining the fuel filter WARNING Risk of injury due to highly flammable substances Highly flammable substances, fluids or gases catch fire. For this reason: S Smoking, naked flames and sources of ignition are strictly forbidden in the danger zone and close pro... - Page 83 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 parts.
- Page 84 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care Fuel filter on engine - changing the fuel filter cartridge A two-stage fuel filter is fitted in the engines. Arrangement of the two-stage fuel filter on en gines with one-stage turbocharging.
- Page 85 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 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.
- Page 86 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 parts.
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Page 87: Bleeding The Fuel System
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 4. Clean the filter cup then fit a new O-ring and screw into the housing. Tightening torque ..25-30 Nm Change the two-stage fuel filter's second fuel filter cartridge. -
Page 88: Changing The Coolant
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 8.4.4 Changing the coolant WARNING Risk of injury due to hot fluid Coolant reaches high temperatures during operation and causes scalding if touched. For this reason: S Always wear protective gloves when holding the coolant drain plug. - Page 89 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care S Unscrew the screw plug on the exhaust manifold on the left engine side and drain the coolant. S Screw the screw plug back in and tighten it.
- Page 90 An incorrect mixture of antifreeze and corrosion inhibitor leads to failure of the 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 at the liquid-cooled exhaust tur...
- Page 91 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care Engine installed horizontally The bleed screws are above the coolant level in the expansion tank In this case, complete filling and bleeding of the cooling system is only possible if the cooling sys...
- Page 92 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care Checking the coolant level WARNING Risk of injury due to hot fluid Coolant reaches high temperatures during operation and causes scalding if touched. For this reason: S Only open the cooling system when the engine is at operating temperature in exceptional circumstan...
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Page 93: Changing The Air Filter
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 8.4.5 Changing the air filter Removing the air filter S Undo the hose clamp S Remove the air filter from the intake neck The second air filter is removed in the same way. -
Page 94: Poly-V-Belt
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 8.4.6 Poly-V-belt WARNING Risk of crushing due to moving parts Rotating and/or linear moving parts can cause injuries. For this reason: S Make sure the engine is stopped before checking and replacing poly-V-belts/V-belts. -
Page 95: Alternator
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 8.4.9 Alternator The alternator is maintenance-free. Observe the following requirements to prevent alternator damage: S Do not switch off the battery master switch. S Do not disconnect the battery whilst the engine is running. - Page 96 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Maintenance and Care 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.
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Page 97: Faults
In the event of a fault, the registered engine parameters are outside of the permissible tolerance limits and the system trips an alarm. The MAN Monitoring and Diagnostics System can reduce the power output of the monitored engine to pre vent follow-on damage. - Page 98 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Faults MMDS CLC 6.5 colour display on the control stand If a value reaches a critical level, a warning mes sage or an alarm is tripped and shown on the dis...
- Page 99 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Faults Display in cover of E-box in engine room The display in the cover of the E-box 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.
- Page 100 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Faults 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.
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Page 101: Decommissioning And Recommissioning
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Decommissioning and recommissioning Decommissioning and recommissioning 10.1 Prerequisite Personal Protective Equipment 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... -
Page 102: Temporary Decommissioning Of The Engine
S Ensure the correct concentration of antifreeze in the coolant and the specified mixing ratio, see publica tion entitled "Fuels, lubricants and coolants for MAN industrial and marine diesel engines". S Close all engine openings (for intake air and exhaust gas), so that no exchange of air can take place inside the engine. - Page 103 Preservation of the intake and exhaust system S Spray corrosion protection oil (MAN-Part No. 09.11002-0025) into the air intake pipe and exhaust pipe. S Close off the openings for suction air and exhaust gas and seal them air tight, with the engine still warm.
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Page 104: Recommissioning Of Shutdown Engines
A routine and careful restart of new or already run engines has a major effect on their operating safety and residual life. The basic aim should be to preserve the engines directly after decommissioning. In this con text the specifications in accordance with the MAN Works Standard M3069 should be followed. User tip Ex Works the engines are preserved in accordance with Works Standard M3069. -
Page 105: Commissioning Of Non-Preserved Engines
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Decommissioning and recommissioning 10.4.2 Commissioning of non-preserved engines In addition to the work sequences for a preserved engine, the commissioning of non-preserved engines requires the following additional work relating to possible deterioration in storage. - Page 106 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Decommissioning and recommissioning 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.
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Page 107: Technical Data
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data Technical data 11.1 Weights and measures Engines with 1-stage turbocharching V12-1550 (D2862 LE426) Specification V8-1000 (D2868 LE426) Unit V12-1400 (D2862 LE446) Weight (dry) 1780 2270 1736 2124 1153 1153... -
Page 108: Engine Data Of Engines For Light Duty
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data 11.3 Engine data of engines for light duty 11.3.1 V8-1000 (D2868 LE426) Engine model V8-1000 (D2868 LE426) Design V 90° Operating principle 4-stroke diesel Combustion system Direct injection Supercharging... -
Page 109: V8-1200 (D2868 Le436)
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data 11.3.2 V8-1200 (D2868 LE436) Engine model V8-1200 (D2868 LE436) Design V 90° Operating principle 4-stroke diesel Combustion system Direct injection Supercharging 2-stage exhaust turbocharging with intercooling and charge-air control (Waste Gate) -
Page 110: V12-1550 (D2862 Le426), V12-1400 (D2862 Le446)
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data 11.3.3 V12-1550 (D2862 LE426), V12-1400 (D2862 LE446) Engine model V12-1550 (D2862 LE426), V12-1400 (D2862 LE446) Design V 90° Operating principle 4-stroke diesel Combustion system Direct injection Supercharging 1-stage exhaust turbocharging with intercooling and charge-air... -
Page 111: V12-1800 (D2862 Le436), V12-1650 (D2862 Le456)
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data 11.3.4 V12-1800 (D2862 LE436), V12-1650 (D2862 LE456) Engine model V12-1800 (D2862 LE436), V12-1650 (D2862 LE456) Design V 90° Operating principle 4-stroke diesel Combustion system Direct injection Supercharging 2-stage exhaust turbocharging with intercooling and charge-air... -
Page 112: V12-1900 (D2862 Le476)
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data 11.3.5 V12-1900 (D2862 LE476) Engine model V12-1900 (D2862 LE476) Design V 90° Operating principle 4-stroke diesel Combustion system Direct injection Supercharging 2-stage exhaust turbocharging with intercooling and charge-air control (Waste Gate) - Page 113 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data Cylinder arrangements Cylinder arrangement V8 Cylinder arrangement V12 Diese Anleitung vor Beginn aller Arbeiten sorgfältig durchlesen! Dies gilt insbesondere für das Kapitel Allgemeine Sicherheitshinweise und die jeweiligen Sicherheitshinweise in den Kapiteln.
- Page 114 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Technical Data Diese Anleitung vor Beginn aller Arbeiten sorgfältig durchlesen! Dies gilt insbesondere für das Kapitel Allgemeine Sicherheitshinweise und die jeweiligen Sicherheitshinweise in den Kapiteln.
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Page 115: Installation Drawings V8
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V8-1200 Installation drawings V8-1200 (D2868 LE436) Identification number for installation drawing: 51.00508-7126, drawn on 08.11.2011... - Page 116 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V8-1200 Identification number for installation drawing: 51.00508-7126, drawn on 08.11.2012...
- Page 117 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V8-1200 Identification number for installation drawing: 51.00508-7126, drawn on 08.11.2011...
- Page 118 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V8-1200 Identification number for installation drawing: 51.00508-7126, drawn on 08.11.2012...
- Page 119 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V8-1200 Identification number for installation drawing: 51.00508-7126, drawn on 08.11.2011...
- Page 120 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V8-1200 Identification number for installation drawing: 51.00508-7126, drawn on 08.11.2012...
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Page 121: Installation Drawings V12
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V12-1800 Installation drawings V12-1800 (D2862 LE436) Identification number for installation drawing: 51.00512-7136, drawn on 22.10.2012... - Page 122 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V12-1800 Identification number for installation drawing: 51.00512-7136, drawn on 22.10.2012...
- Page 123 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V12-1800 Identification number for installation drawing: 51.00512-7136, drawn on 22.10.2012...
- Page 124 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V12-1800 Identification number for installation drawing: 51.00512-7136, drawn on 22.10.2012...
- Page 125 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V12-1800 Identification number for installation drawing: 51.00512-7136, drawn on 22.10.2012...
- Page 126 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Installation drawings V12-1800 Identification number for installation drawing: 51.00512-7136, drawn on 22.10.2012...
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Page 127: Index
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Index 14Index 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 128: Abbreviations
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Index 14.1 Abbreviations ..Ampere ..Maximum ..Ampere hours .. -
Page 129: Technical Lexicon
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Index 14.2 Technical lexicon CAN, Controller Area Network, developed by Bosch in the early 1980s, was specially developed for fast serial data interchange between electronic control units in motor vehicles. With CAN, each message to be sent is clearly identified by a mes... -
Page 130: Index
MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Index 14.3 Index Air filter, changing ...... - Page 131 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Index Faults, 95 Limitation of liability ......
- Page 132 MAN marine diesel engines D2868 LE4.. / D2862 LE4.. Index Safety equipment ......Technical data .
- Page 134 MAN Truck & Bus AG Vogelweiherstraße 33 90441 Nürnberg Germany A member of the MAN Group Printed in Germany 51.99493-8596...