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Summary of Contents for Man D 2848 LE 401
- Page 1 D 2848 LE 401 / 403 / 405 D 2840 LE 401 / 402 / 407 D 2842 LE 401 / 402 / 403 / 406 / 408 / 411 / 412 / 413...
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Page 3: Preface
You can find the approved products in the internet under: −http://www.man-mn.com/ " Products & Solutions " E-Business− 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 4: Instructions
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 5: Table Of Contents
Contents Preface ..............Instructions . -
Page 6: 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 7 Declaration...
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Page 8: 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 9: Safety Regulations
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... - Page 10 Safety regulations 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 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 12 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.
- Page 13 Safety regulations For this reason do not let engine oil get into 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. ∗...
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Page 14: Commissioning And Operation
Commissioning and operation Engine views D 2842 LE 401... - Page 15 Commissioning and operation 1 Heat exchanger and coolant surge tank 2 Coolant filler neck 3 Intercooler 4 Relief valve on coolant surge tank 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...
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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...
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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. Caution: 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. Ensure that the gearbox is in neutral. Caution: When starting do not use any additional starting aids (e.g. injection with starting pilot). 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 System Be1
Commissioning and operation For repeated starting turn the key back to OFF. If the engine is kept idling for long periods it may cool down and thus start to emit white or blue smoke. We therefore recommend that you do not let the engine idle for more than 5 minutes. It is well known that with any internal combustion engine wear is higher during idling. - Page 21 Commissioning and operation Operation of the engine monitoring system BE1 The engine monitoring system BE1 warns the ship operator if important engine oper- ating values are outside the permissible tolerance range. The display unit of the engine monitoring system (see picture) is installed in the main navigating stand and, as an option, in the secondary navigating stand (fly- bridge) too.
- Page 22 Commissioning and operation D Short-term reduction of the engine speed below 800 rpm, to again achieve higher en- gine speeds Functional test of the check lamps If no alarm is raised, the check lamps may be checked. Upon pressing the button “Test”, all check lamps must come on.
- Page 23 Commissioning and operation The D 2848 LE 401 is equipped with a monitoring and diagnostic system MMDS option- ally. On the control console and alternatively on other control stands, the following display de- vices are available for monitoring operation: 1. Analog round instruments, see below 2.
- Page 24 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...
- Page 25 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 26 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 27 Commissioning and operation Page 3 Actual value (example) Engine speed 2100 Intake air vacuum mbar Charging pressure 1,86 °C Exhaust temperature T.A. °C Exhaust temperature T.B. Page 4 Actual value (example) Engine speed 2100 Fuel consumption Engine load The pages are scrolled using the “PAGE” key. Each time the key is pressed, the screen moves up to the next page.
- Page 28 Commissioning and operation Alarms If an engine alarm from the central unit MMDS or an alarm configured by the user is is- sued, the built-in buzzer is activated and the LED “Alarm” flashes. At the same time, the monitor switches automatically to the alarm screen. The new alarm is entered in the first line as a flashing message.
- Page 29 Commissioning and operation Visual Quit / Test: Standard function: visual acknowledgement, i.e. all flashing alarm texts in the currently visible alarm screen switch to T E S T constant representation if the horn was acknowledged beforehand; the red alarm LED integrated in the front plate is also switched from flashing to continuous lighting.
- Page 30 Commissioning and operation Menu functions By holding the “ALARMS” key (for at least 5 seconds), you enter the configuration menu. The keys are now given the significance described at “Menu function”. The new alloca- tion is shown in the bottom line in continuous black: Escape function Move function Enter function...
- Page 31 Commissioning and operation Display in BAR Display in PSI > (BAR) < (PSI) After selection and acceptance, all the settings for language and unit have been con- cluded and highlighted accordingly in black. The selection cursor jumps to the second last line to the item “exit”: >exit<...
- Page 32 Commissioning and operation >exit< Back get-mmds-time ALARMS You return to the main menu by pressing the PRG key or the Menu key P rg M en the event of an input error, you can use the function “back” to repeat the input. An additional function makes it possible to download the system time of the MMDS cen- tral unit into the display module.
- Page 33 Commissioning and operation 4. Engine room panel MMDS-EP MAN MARINE DIESEL Motordrehzahl 1835 upm Motoroeldruck 4.3 bar Engine run Kuehlwassertemp. Ladelufttemperatur Alarm Motoroeltemperatur 120 C System Fail. 51.27720−7018 TYP MMDS−EP PAGE RESET TEST ALARMS The functions of the keys and of the LCD displays are the same as those on the MMDS-LC (see operating instructions for MMDS-LC).
- Page 34 (the engine must stop immediately when the button is pressed once). 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.
- Page 35 Commissioning and operation 2. “Increase engine speed” function: The “Increase engine speed” function is set (function switch II−8). The engine speed of the power unit is raised prior to engaging the clutch and after disengaging the clutch it is lowered again to idling speed. Between the clutch engaging operations, individual delays (waiting periods BEFORE and AFTER clutch engaging) can be set.
- Page 36 Commissioning and operation 2. Press the key “Command takeover” and keep it pressed. 3. Set the control lever of the command master in position “Á gearbox forwards / re- verse”. The “Warming Up” function is indicated acoustically by a short “double beep” tone and visually by a brief, rhythmic extinguishing of the command master lighting.
- Page 37 Commissioning and operation 1. Engine speed synchronisation (only twin-engine systems) 2. Trolling The “Syn./Trol.” key can be used to operate both functions in parallel, but not sim- ultaneously. Engine speed synchronisation (only possible with twin-engine systems) If the special function “Engine speed synchronisation” has been enabled in the setting units, twin-engine systems provide the possibility to synchronise the engine speeds of both drive engines.
- Page 38 Commissioning and operation Pressing the “Syn./Trol.” key (press once) enables the “Trolling” function. Pres- sing again (press once) disables the function once again. It is only possible to enable or disable the trolling function on the active control SYN/TROL stand when the command master lever (both command master levers in the case twin-engine systems) is (are) in the “Neutral”...
- Page 39 Commissioning and operation When position  is reached, the clutch is in the smallest possible slip position (0% slip / frictional connection) and the engine speed has reached the set value for “Maximum en- gine speed for trolling”. 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).
- Page 40 Commissioning and operation . “Command master calibration and enable of control stands” must have been carried out. Otherwise, the command can only be taken over at control stand 1. Execution: − Set the control lever of the command master to the “Neutral position”. −...
- Page 41 Commissioning and operation 1st step: Command request on the selected control stand. Execution: − Set the control lever of the command master in the takeover position (“Neutral” position or same travel direction as the command master that is in command). −...
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Page 42: Shutting Down
Commissioning and operation Shutting down After the engine has been running at a high 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. -
Page 43: 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 44 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 45 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...
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Page 46: 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 47 Maintenance and care Parallel fuel filter Draining moisture: Unscrew drain plugs at every oil change until moisture has been discharged and clean fuel flows out. Changing fuel filter Only when engine is switched off D Loosen filter with tape wrench and remove it D Wet seal on new filter with fuel D Screw on filter by hand...
- Page 48 Maintenance and care Changing fuel filter D Loosen filter with tape wrench and remove it D Wet seal on new filter with fuel D Screw on filter by hand D After this, bleed the fuel system D Check filter for leaks Caution: Used fuel filters are classed as dangerous waste and must be dis-...
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Page 49: 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. - Page 50 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, large cap). When topping up do not add cold coolant if the engine is still warm from operation.
- Page 51 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, large cap)
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Page 52: V-Belts
Maintenance and care V-belts Checking condition If, in the case of a multiple belt drive, wear or differing tensions are found, always re- place the complete set of belts. 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. -
Page 53: 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 54: Technical Data
Technical data Model D 2848 LE 401 / 403 / 405 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... - Page 55 In-line pump, V-saddle-mounted Governor Centrifugal governor (variable-range speed governor) with smoke stop Start of delivery D 2848 LE 401 22° ± 1° before TDC D 2848 LE 403 24° ± 1° before TDC up to engine No..9211 019 ..
- Page 56 Technical data Model D 2840 LE 401 / 402 / 407 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 18 270 cm...
- Page 57 Technical data Fuel system Injection In-line pump, V-saddle-mounted Governor Centrifugal governor (variable-range speed governor) with smoke stop Start of delivery D 2840 LE 401 24° ± 1° before TDC D 2840 LE 402 15° ± 0,5° before TDC with optimised consumption with optimised NO 12°...
- Page 58 Technical data Model D 2842 LE 401 / 402 / 403 / 406 / 408 D 2842 LE 411 / 412 / 413 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...
- Page 59 Technical data Start of delivery 22° ± 0,5° before TDC D 2842 LE 401 / 402 D 2842 LE 403 with optimised consumption 15° ± 0,5° before TDC 12° ± 0,5° before TDC with optimised NO D 2842 LE 406 24°...
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Page 60: 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 61 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...
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Page 62: Index
Index Alternator ....... . Maintenance and care ....45–55 Bleeding the fuel system . - Page 64 MAN Nutzfahrzeuge AG Geschäftseinheit Motoren Vogelweiherstraße 33 D−90441 Nürnberg Ein Unternehmen der MAN Gruppe Printed in Germany 51.99598−8498...
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