Man D 0836 le 401 User manual

3

Operating Instructions −

MAN Marine Diesel Engines

4

Preface

5

Dear Customer,

these Operating Instructions are intended to familiarize you with your new MAN Diesel

engine and how it operates.

This manual contains information on “Fuels, Lubricants and Coolants for MAN Diesel En-

gines”.

This manual is supplemented by the publication “Service record book”.

Note:

All three publications belong to the engine and must always be kept ready to

hand near the engine in the engine room.

Comply in full with instructions relating to operation, prevention of accidents and

environmental protection.

MAN Diesel engines are developed and manufactured in line with the latest state of the

art. However, trouble-free operation and high performance can only be achieved if the

specified maintenance intervals are observed and only approved fuels, lubricants and

coolants are used.

Note:

Only use fuel, coolants and lubricants in accordance with MAN’s regulations

otherwise the manufacturer’s warranty will not apply!

For basic information on the fuels see the publication “Fuels, Lubricants and

Coolants for MAN Diesel Engines”.

You can find the approved products in the internet under:

−http://www.man-mn.com/ "Products & Solutions "E-Business−

It is 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.

Yours faithfully,

MAN Nutzfahrzeuge Aktiengesellschaft

Werk Nürnberg

Subject to change to keep abreast with technological progress.

No parts of this publication may be reproduced or translated without prior written permis-

sion of MAN. MAN explicitly reserves all rights according to copyright law.

MTDB Technical status: 03.2006 51.99493−8526

Instructions

6

Important instructions which concern technical safety and protection of persons are em-

phasised as shown below.

Danger:

This refers to working and operating procedures which must be complied with in

order to rule out the risk to persons.

Caution:

This refers to working and operating procedures which must be complied with in

order to prevent damage to or destruction of material.

Note:

Explanations useful for understanding the working or operating procedure to be

performed.

Fitting flat seals / gaskets

Flat seals / gaskets are often inserted with sealing agents or adhesives to make fitting

them easier or to achieve better sealing. Flat seals may slip in operation due to the “sew-

ing-machine” effect, in particular if they are used between parts with different rates of lin-

ear expansion under heat (e.g. aluminium and cast iron), and leaks may then occur.

Example:

the cap of the front crankshaft seal. If a sealing agent or an adhesive is used here the flat

seal will move inwards in the course of time as a result of the different expansion rates of

the materials. Oil will be lost, for which the shaft seal may be thought to be responsible.

Flat seals / gaskets can be fitted properly only if the following points are ob-

served:

DUse only genuine MAN seals / gaskets

DThe sealing faces must be undamaged and clean

DDo not use any sealing agent or adhesive −as an aid to fitting the seals a little grease

can be used if necessary so that the seal will stick to the part to be fitted

DTighten bolts evenly to the specified torque

Contents

7

Preface 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaracion 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplates 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety regulations 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning and operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine views D 0836 LE 401 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First commissioning 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation monitoring system 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer CAN-Master 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting down 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and care 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication system 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling system 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-belts 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temporary decommissioning of engines 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting table 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For data see original declaration

If required this declaration is enclo-

sed with the delivery note.

Declaracion

8

Declaracion

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.

Engine model:

Design:

Engine number:

Rating / speed:

Note:

The manufacturer of the complete ready-to-use machine in which this engine is to be

installed must take the further action necessary in the context of indirect safety-re-

lated engineering and provision of instructions to ensure that the ready-to-use ma-

chine complies with the requirements of the EC directive on machines.

The engine must not be put into operation until the complete machine satisfies the

conditions laid down in the EC directive on machines 89/392/EEC, most recently

amended by 93/44/EEC, or the latest amendment of said directive.

MAN Nutzfahrzeuge Aktiengesellschaft,

Vogelweiherstraße 33

D−90441 Nürnberg

Declaracion

9

Nameplates

10

In all your correspondence please always

quote engine model, serial number and

job number (Order number).

For this reason it is advisable to read off

the data from the engine type plates be-

fore putting the engine into operation and

to enter them in the appropriate spaces.

The engine type plates are on the crank-

case.

Typ .....................................................................

delivered on ......................................................................

installed on ......................................................................

Engine serial number ......................................................................

Order number ......................................................................

MAN Nutzfahrzeuge Aktiengesellschaft

Typ

Motor-Nr. / Engine No.

NI/II

Temp. C

Werk Nürnberg Germany

:

MAN Nutzfahrzeuge AktiengesellscMAN Nutzfahrzeuge Aktiengesellschaft

:

Altitude mRating BHP

Job No Rating kW Speed rpm

Serial NoModelYear

−0219

Aufstellhohe m uNNLeistg. PS

Drehz. 1/min

Leistung kWWerk−Nr.

Motor−Nr.TypBauj.

°

Safety regulations

11

General notes

Day-to-day use of power engines and the service products (fuels, lubricants, cool-

ants) necessary for running them presents no problems if the persons occupied

with their operation, maintenance and care are given suitable training and think as

they work.

This summary is a compilation of the most important regulations. These are broken down

into main sections which contain the information necessary for preventing injury to per-

sons, damage to property and pollution. In addition to these regulations those dictated by

the type of engine and its site are to be observed also.

Important:

If, despite all precautions, an accident occurs, in particular through contact with caustic

acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the

eyes etc., consult a doctor immediately.

Safety regulations

12

1. Regulations designed to prevent accidents with injury to persons

During commissioning, starting and operation

DBefore 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.

DFor reasons of safety we recommend you attach a notice to the door of

the engine room prohibiting the access of unauthorized persons and that

you draw the attention of the operating personal to the fact that they are

responsible for the safety of persons who enter the engine room.

DThe engine must be started and operated only by authorized personnel.

Ensure that the engine cannot be started by unauthorized persons.

DWhen the engine is running, do not get too close to the rotating parts.

Wear close-fitting clothing.

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

−risk of burns.

ËË

DFor safety reasons a separate, functioning red emergency-stop-

button for each engine must be installed at every bridge (the engine

must stop immediately when the button is pressed once).

DExhaust 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.

DKeep vicinity of engine, ladders and stairways free of oil and grease.

Accidents caused by slipping can have serious consequences.

During maintenance and care

DAlways 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. Do not get too close to rotating parts.

Safety regulations

13

DChange the oil when the engines is warm from operation.

Caution:

There is a risk of burns and scalding. Do not touch oil drain plugs or oil

filters with bare hands.

ËË

DTake into account the amount of oil in the sump. Use a vessel of suffi-

cient size to ensure that the oil will not overflow.

DOpen the coolant circuit only when the engine has cooled down.

If opening while the engine is still warm is unavoidable, comply with the

instructions in the chapter entitled “Maintenance and Care”.

ËËË

DNeither tighten up nor open pipes and hoses (lube oil circuit, coolant cir-

cuit and any additional hydraulic oil circuit) during the operation.

The fluids which flow out can cause injury.

DFuel is inflammable. Do not smoke or use naked lights in its vicinity. The

tank must be filled only when the engine is switched off.

DWhen using compressed air, e.g. for cleaning the radiator, wear goggles.

DKeep service products (anti-freeze) only in containers which can not be

confused with drinks containers.

DComply with the manufacturer’s instructions when handling batteries.

Caution:

Accumulator acid is toxic and caustic. Battery gases are explosive.

Safety regulations

14

2. Regulations designed to prevent damage to engine and premature wear

Do not demand more from the engine than it is able to supply in its intended application.

Detailed information on this can be found in the sales literature. The injection pump must

not be adjusted without prior written permission of MAN Nürnberg.

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”.

In addition to the above, note the following points:

DNever let the engine run when dry, i.e. without lube oil or coolant.

DWhen starting do not use any additional starting aids (e.g. injection with starting pilot).

DUse only MAN-approved service products (fuel, engine oil, anti-freeze and anti-cor-

rosion agent). Pay attention to cleanliness. The Diesel fuel must be free of water. See

“Maintenance and care”.

DHave the engine maintained at the specified intervals.

DDo not switch off the engine immediately when it is warm, but let it run without load for

about 5 minutes so that temperature equalization can take place.

DNever put cold coolant into an overheated engine. See “Maintenance and care”.

DDo not add so much engine oil that the oil level rises above the max. marking on

the dipstick. Do not exceed the maximum permissible tilt of the engine.

Serious damage to the engine may result if these instructions are not adhered to.

DAlways ensure that the testing and monitoring equipment (for battery charge, oil pres-

sure, coolant temperature) function satisfactorily.

DComply with instructions for operation of the alternator. See “Maintenance and care”.

DDo not let the raw water pump run dry. If there is a risk of frost, drain the pump when

the engine is switched off.

Safety regulations

15

3. Regulations designed to prevent pollution

Engine oil and filter elements / cartridges, fuel / fuel filter

DTake old oil only to an old oil collection point.

DTake strict precautions to ensure that no oil or Diesel fuel gets into the drains or the

ground.

The drinking water supply could be contaminated.

DFilter elements are classed as dangerous waste and must be treated as such.

Coolant

DTreat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.

DWhen disposing of spent coolant comply with the regulations of the relevant local auth-

orities.

Safety regulations

16

4. Notes on safety in handling used engine oil ∗

Prolonged or repeated contact between the skin and any kind of engine oil decreases the

skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil

also contains dangerous substances which have caused skin cancer in animal experi-

ments. If the basic rules of hygiene and health and safety at work are observed, health

risks are not to the expected as a result of handling used engine oil.

Health precautions:

DAvoid prolonged or repeated skin contact with used engine oil.

DProtect your skin by means of suitable agents (creams etc.) or wear protective gloves.

DClean skin which has been in contact with engine oil.

−Wash thoroughly with soap and water. A nailbrush is an effective aid.

−Certain products make it easier to clean your hands.

−Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.

DAfter washing apply a fatty skin cream to the skin.

DChange oil-soaked clothing and shoes.

DDo not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly

−Engine oil can endanger the water supply −

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.

∗Adapted from “Notes on handling used engine oil”.

Notes

17

.............................................................................................................................................

Commissioning and operation

18

Engine views D 0836 LE 401

11

12

3

4

5

6

789

10

12 13

1415

16

17

18

Commissioning and operation

19

1 Coolant filler neck

2 Intercooler

3 Air filter

4 Starter motor

5 Oil filler neck

6 Oil dipstick

7 Oil filter

8 Injection pump

9 Prestrainer

10 Fuel filter

11 Water pump (engine coolant circuit)

12 Crankcase breather

13 Hand primer

14 Generator

15 Raw water pump

16 Oil drain plug

17 Heat exchanger

18 Turbocharger, liquid-cooled

Commissioning and operation

20

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. Initial run-in

should be at varying speeds After this initial run-in, the engine should be brought up to

full output gradually.

Note:

Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”).

Otherwise the manufacturer’s warranty will become null and void.

Filling with fuel

Caution:

Fill the tank only when the engine is switched off! Pay attention to cleanliness.

Do not spill fuel.

Use only approved fuels, see brochure “Fuels, lubricants etc.”.

Filling-in of coolant

Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze

agent on the ethylene glycole basis or anti-corrision agent.

See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.

DPour in coolant slowly via expansion tank, see page 65

DFor coolant filling quantity, see “Technical data”

Man D 0836 LE 401 User manual

Popular Engine manuals by other brands