Escolar Documentos
Profissional Documentos
Cultura Documentos
V8 D2868 LE4..
V12 D2862 LE4..
2015
MAN Truck & Bus AG
Vogelweiherstrasse 33
D - 90441 Nuremberg
Tel.: +49 911 / 4201745
Fax: +49 911 / 4201932
EMail: EngineDocumentation@man.eu
Internet: www.manengines.com
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MAN marine diesel engines D2868 LE4.. / D2862 LE4.. LE4..
Contents
Printer's imprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Information about the installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Notes on using the installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Notes on EPA Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Supplementary documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Fitting a new engine for a ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Installation acceptance tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.10 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Engine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Requirements of engine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Engine weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Maximum permitted angle of inclination for engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6 Resilient mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1 Selection of a suitable resilient mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2 Resilient mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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11 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.1 Basic design concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.2 Exhaust gas system structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.3 Permitted exhaust back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
12 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
12.1 Seawater cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
12.2 Seawater inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
12.3 Seawater supply components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12.4 Seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
12.5 Gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12.6 Choice of materials for pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
14 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
14.1 Diagram of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
14.2 Fuel pre-filter with water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
14.3 Arrangement of the fuel filter with water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14.4 Additional fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14.5 Fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
15 Propeller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
15.1 Fixed pitch propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
15.2 Load indication on MAN Monitoring Diagnosis System (MMDS) display . . . . . . . . . . . . . . . 92
15.3 Operating ranges for marine engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
15.4 Controllable pitch propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
16 Cabin heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
16.1 Cabin heater diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
16.2 Cabin heater connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
16.3 Cabin heater thermal output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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Contents
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Contents
34 Tightening torques for bolted connections as per factory norm M 3059 . . . . . . . . . . . . . . . . 173
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Contents
40 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
40.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
40.2 Technical lexicon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
40.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
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Contents
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Foreword
1 Foreword
NOTE
Key parameters for the operational reliability of the engines are recorded and evaluated during
commissioning.
Therefore:
S Commissioning is to be performed solely by personnel authorised by MAN.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Foreword
NOTE
Violation of federal law 40CFR 1068.105(b)
Therefore:
S Failing to follow these instructions when installing a certified engine in a vessel violates federal law
40CFR 1068.105(b) and is subject to fines or other penalities as described in the Clean Air Act.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Foreword
WARNING
Risk of injury due to incorrect replacement parts
Incorrect or defective replacement parts can lead to damage, malfunction or total failure and impair
safety.
Therefore:
S Only use genuine MAN replacement parts
User tip
Indicate the engine model, engine number and order number in all correspondence and enquiries,
see Operator's Manual.
Order replacement parts through authorised dealers or directly from MAN. For address, see page 2.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Foreword
Warnings
Warnings are indicated by symbols in this Operator's Manual. The warnings are preceded by sig
nal words which indicate the extent of the danger.
Always heed these warnings and act carefully to prevent accidents, injury or damage.
DANGER
Describes an immediately dangerous situation that will lead to injury or death if not avoided.
WARNING
Describes a possibly dangerous situation that can lead to injury or death if not avoided.
CAUTION
Describes a possibly dangerous situation that can lead to slight or moderately severe injury if not
avoided.
NOTE
Describes a possibly dangerous situation that can lead to damage if not avoided.
User tip
Tips, recommendations and information for efficient and trouble-free operation.
ENVIRONMENTAL NOTE
Tips on conduct with respect to environmental protection.
General notes
• This symbol indicates a first-level listing.
► This symbol indicates an action/a consequence of an action.
(1) This symbol indicates an illustrated item in the text.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Installation planning
Installation planning
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Installation planning
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
General safety instructions
DANGER
Danger due to non-intended use
Any use of the engine that goes beyond and/or is different to the intended use can lead to dangerous
situations and invalidates the operating permit.
Therefore:
S Only use the engine in accordance with its intended use.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
General safety instructions
WARNING
Risk of injury due to illegible symbols
Over the course of time, labels and symbols can get dirty or become illegible!
Therefore:
S Ensure that all safety, warning and operating notices remain easily legible at all times.
S Clean or replace illegible safety, warning and operating notices
Access forbidden
Access to areas displaying this sign is forbidden.
Electrical voltage
Only electrical experts are allowed to work in areas displaying this sign.
Unauthorised persons are not allowed to enter areas displaying this sign.
Hot surfaces
Hot surfaces such as hot engines and hot fluids are not always discernible. Do not touch
these surfaces without wearing protective gloves.
Risk of injury
Risk of injury if the instructions in the Operator's Manual are not followed.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Planning of engine installation
NOTE
Engine damage due to incorrect configuration of components in the engine environment.
Therefore:
S Adapt all components in the engine environment to the engine with respect to design and dimen
sioning .
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Planning of engine installation
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Planning of engine installation
The engines
The illustrations on page 18 show views of a V12 engine and a V8 engine, in each case without the gear
box.
The V8 and V12 engines are available with various power ratings, depending on the particular application.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Planning of engine installation
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MAN marine diesel engines D2868 LE4 / D2862 LE4
Accessibility of the engine in the engine room
DANGER
It must be possible to stop the engine quickly and reliably in an emergency, even in the engine
room.
Therefore:
S The red emergency stop button on the E-box must be quickly and reliably accessible!
The E-box (terminal box) (1) must be mounted in the engine room so that it is easily accessible. There is
an emergency stop button (2) on the E-box.
A description of the E-box can be found on page 105.
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MAN marine diesel engines D2868 LE4 / D2862 LE4
Accessibility of the engine in the engine room
NOTE
High engine reliability due to regular inspection and maintenance
Lower service costs due to reduced time outlays
Therefore:
S When installing the engine, ensure that there is enough space available to perform the regular main
tenance work.
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MAN marine diesel engines D2868 LE4 / D2862 LE4
Accessibility of the engine in the engine room
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MAN marine diesel engines D2868 LE4 / D2862 LE4
Accessibility of the engine in the engine room
S Coolant filling
(description in "Commissioning" section")
Height of deck above filler cap (9):
H=500 mm (recommended).
S Coolant level check (10)
(description in "Commissioning" section).
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MAN marine diesel engines D2868 LE4 / D2862 LE4
Accessibility of the engine in the engine room
NOTE
Simple visual inspections enable the causes of operating faults to be detected early.
Therefore:
S There must be enough space available to inspect the engine for oil, coolant or seawater leaks.
S Hose connections and pipe lines from and to the engine must be easily accessible.
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MAN marine diesel engines D2868 LE4 / D2862 LE4
Accessibility of the engine in the engine room
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine foundation
5 Engine foundation
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine foundation
The weights are based on the engine without lube oil and coolant. To determine the weight of the engine
ready for operation, the weight of the lube oil and coolant must be added.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine foundation
a b
NOTE
The angle of 5_ to the counter-flywheel side is only permissible whilst the ship is moving.
Therefore:
S The installation inclination to the counter-flywheel side is 0_.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine foundation
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Resilient mounting
6 Resilient mounting
NOTE
The resilient engine mounts cannot absorb vibrations caused by incorrect alignment of the drive line or
vibrations excited by the propeller.
Therefore:
S Carefully align the drive line, see page 159.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Resilient mounting
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Resilient mounting
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Resilient mounting
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine and flange-mounted gearbox
DANGER
Danger to life due to rotating machine parts
Therefore:
S For safety reasons, rotating machine parts (shafts, flanges) must be equipped with suitable accidental-
contact protection. Observe accident prevention regulations!
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine and flange-mounted gearbox
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine and flange-mounted gearbox
NOTE
Perform a precise installation analysis, depending on project.
Therefore:
S Request an installation drawing with detailed dimensions of the flywheel and flywheel housing.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine and flange-mounted gearbox
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Transmission of power by propeller shafts
8.1.1 Drive line consisting of engine, highly resilient coupling, propeller shaft
and gearbox
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Transmission of power by propeller shafts
8.1.2 Drive line consisting of engine, resilient coupling with flange bearing, pro
peller shaft and gearbox
Power take-off on the engine is via a resilient coupling with flange bearing (see bottom of left page for illus
tration).
This concept requires more construction space due to the flange bearing, but allows a working angle of up
to 9_.
(1) Engine
(2) Resilient engine mounting
(3) Resilient coupling with flange bearing, see page 42
(4) Free-standing gearbox
(5) Propeller shaft, see page 43
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Transmission of power by propeller shafts
8.3 Flywheels
NOTE
Perform a precise installation analysis, depending on project.
Therefore:
S Request an installation drawing with detailed dimensions of the flywheel and flywheel housing.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Transmission of power by propeller shafts
8.4 Couplings
DANGER
Danger to life due to rotating machine parts
Therefore:
S For safety reasons, rotating machine parts (shafts, flanges) must be equipped with suitable accidental-
contact protection. Observe accident prevention regulations!
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Transmission of power by propeller shafts
b1
b2
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Transmission of power by propeller shafts
Exception:
In the case of a spatially-angled propeller shaft,
the input and output shafts do not lie in one plane.
To achieve a steady output motion, the inside pro
peller shaft forks must be twisted against one an
other so that they both lie within the angled plane
produced by their joints. In addition, the spatial
working angles must be the same.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine room ventilation
NOTE
Damage to electronic components in the E-box
Therefore:
S Temperature outside the E-box: max. 60_C.
S Temperature inside the E-box: max. 70_C.
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MAN industrial diesel engines D2868 LE4.. / D2862 LE4..
Engine room ventilation
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Engine room ventilation
Medium Duty
D2868 LE422 588 (800) 2100 2580
D2868 LE425 588 (800) 2100 2490
D2862 LE422 749 (1019) 2100 3840
D2862 LE425 749 (1019) 2100 3200
D2862 LE432 882 (1200) 2100 3950
D2862 LE435 882 (1200) 2100 3440
D2862 LE463 1029 (1400) 2100 4100
D2862 LE466 1029 (1400) 2100 3910
Heavy Duty
D2868 LE421 441 (600) 1800 2040
D2868 LE424 441 (600) 1800 2150
D2862 LE421 662 (900) 1800 3280
D2862 LE424 662 (900) 1800 2910
D2862 LE431 551 (750) 1800 3150
D2862 LE434 551 (750) 1800 2700
D2862 LE444 735 (1000) 1800 2950
The air requirement indicated in the table is the combustion air requirement per engine.
The air intake openings in the engine room have to be dimensioned to accept this volumetric flow.
9.3.1 Fans
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MAN industrial diesel engines D2868 LE4.. / D2862 LE4..
Engine room ventilation
NOTE
Water ingress causes irreparable engine damage
Therefore:
S Sea foam and spray is not allowed to reach the engines.
Airflow design
If a fast ship has a streamlined airflow and the air 5
stream is used effectively, the airflow volume can
be optimised. 6
A Free cross-section
(4) Deck
(5) Airflow
(6) Ship's side
The free cross-section A of the air inlet is related
to the narrowest point of the complete air supply
route. It is dimensioned according to the air re
quirement of the engines in accordance with the
table on page 46.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Combustion air system and charging
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Combustion air system and charging
NOTE
Exceeding the maximum permissible intake depression causes a lack of power, black smoke
and, as a consequence, engine damage
Therefore:
S If the maximum permissible intake depression is exceeded, the engine monitoring system trips an
alarm.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Combustion air system and charging
NOTE
Exceeding the maximum permissible combustion air temperature downstream of the intercooler
leads to engine damage caused by thermal overload
Therefore:
S If the maximum permissible combustion air temperature is exceeded, the engine monitoring system
trips an alarm.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Combustion air system and charging
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
11 Exhaust system
DANGER
Exhaust gases are toxic and hot
Therefore:
S The exhaust gas system must be completely gas-tight.
S The exhaust gas system must have fireproof insulation.
Never let water get into the engine via the exhaust
system. If the engine and exhaust gas outlet are
installed in a low position just above or below the
water line, an elbow followed by a descending ex
haust gas line (“gooseneck") (1) must be installed
in the pipe routing to prevent water entering the
engine when reversing or in the event of swell.
It is not permissible to provide a single common
exhaust system for several engines. In the case of
multi-engine layouts a separate exhaust system for
each engine is obligatory, so that with one engine
running, no exhaust gas can enter the other en
gine/s.
NOTE
If seawater enters the engine, it causes irreparable damage.
Therefore:
S Install an elbow in the exhaust gas line.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
5 4
3
2
1
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
Average back pressure (pressure drop) in hPa (mbar) per 1 m exhaust pipe, depending on the ex-
haust gas mass flowrate in kg/h and the clear diameter in mm
Exhaust gas
Mass flowrate * Diameter in mm
kg / h 80 100 120 140 160 180 200
800 9.9 3.0 1.2 0.5 0.3 0.1 0.1
900 12.6 3,8 1.5 0.6 0.3 0.2 0.1
1000 15.5 4.7 1.8 0.8 0.4 0.2 0.1
1100 18.8 5.7 2.2 1.0 0.5 0.3 0.2
1200 22.3 6.8 2.6 1.1 0.6 0.3 0.2
1300 −−− 8.0 3.0 1.3 0.7 0.4 0.2
1400 −−− 9.3 3.5 1.6 0.8 0.4 0.2
1500 −−− 10.7 4.0 1.8 0.9 0.5 0.3
1600 −−− 12.1 4.6 2.0 1.0 0.5 0.3
1700 −−− 13.7 5.2 2.3 1.1 0.6 0.4
1800 −−− 15.3 5.8 2.6 1.3 0.7 0.4
1900 −−− 17.1 6.5 2.9 1.4 0.8 0.4
2000 −−− 18.9 7.2 3.2 1.6 0.8 0.5
2100 −−− 20.1 7.9 3.5 1.7 0.9 0.5
2200 −−− 22.9 8.7 3.8 1.9 1.0 0.6
2300 −−− −−− 9.5 4.2 2.1 1.1 0.6
2400 −−− −−− 10.4 4.6 2.2 1.2 0.7
2500 −−− −−− 11.2 5.0 2.5 1.3 0.8
2600 −−− −−− 12.2 5.4 2.6 1.4 0.8
2700 −−− −−− 13.1 5.8 2.9 1.5 0.9
2800 −−− −−− 14.1 6.2 3.1 1.6 0.9
2900 −−− −−− 15.1 6.7 3.3 1.8 1.0
3000 −−− −−− 16.2 7.1 3.5 1.9 1.1
3100 −−− −−− 17.3 7.6 3.8 2.0 1.1
3200 −−− −−− 18.4 8.1 4.0 2.1 1.2
3300 −−− −−− 19.6 8.6 4.2 2.3 1.3
3400 −−− −−− 20.8 9.2 4.5 2.4 1.4
3500 −−− −−− 22.0 9.7 4.8 2.6 1.5
3600 −−− −−− −−− 10.3 5.0 2.7 1.5
3700 −−− −−− −−− 10.8 5.3 2.9 1.6
3800 −−− −−− −−− 11.4 5.6 3.0 1.7
3900 −−− −−− −−− 12.0 5.9 3.2 1.8
4000 −−− −−− −−− 12.7 6.2 3.3 1.9
4100 −−− −−− −−− 13.3 6.5 3.4 2.0
4200 −−− −−− −−− 14.0 6.8 3.6 2.1
4300 −−− −−− −−− 14.6 7.1 3.7 2.2
4400 −−− −−− −−− 15.2 7.4 3.8 2.3
4500 −−− −−− −−− 15.9 7.7 4.0 2.4
4600 −−− −−− −−− 16.5 8.0 4.1 2.5
* For engine values, see technical data in the appendix
Engine and gearbox installation planning
56
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
Average back pressure (pressure drop) in hPa (mbar) per 90_ manifold (R/d = 1.5), depending on
the exhaust gas mass flowrate in kg/h and the free diameter in mm
Exhaust gas
Mass flowrate * Diameter in mm
kg / h 80 100 120 140 160 180 200
800 9.8 4.0 1.9 1.1 0.6 0.4 0.3
900 12.3 5.1 2.5 1.3 0.8 0.5 0.3
1000 15.2 6.2 3.0 1.6 1.0 0.6 0.4
1100 18.4 7.6 3.6 2.0 1.2 0.7 0.5
1200 21.9 8.9 4.3 2.3 1.4 0.9 0.6
1300 −−− 10.6 5.1 2.8 1.6 1.0 0.7
1400 −−− 12.2 5.9 3.2 1.9 1.2 0.8
1500 −−− 14.1 6.8 3.7 2.2 1.3 0.9
1600 −−− 16.0 7.7 4.2 2.4 1.5 1.0
1700 −−− 18.0 8.7 4.7 2.8 1.7 1.1
1800 −−− 20.2 9.8 5.3 3.1 1.9 1.3
1900 −−− −−− 10.9 5.9 3.4 2.2 1.4
2000 −−− −−− 12.0 6.5 3.8 2.4 1.6
2100 −−− −−− 13.3 7.2 4.2 2.6 1.7
2200 −−− −−− 14.6 7.9 4.6 2.9 1.9
2300 −−− −−− 15.9 8.6 5.0 3.1 2.1
2400 −−− −−− 17.3 9.4 5.5 3.4 2.3
2500 −−− −−− 18.8 10.2 6.0 3.7 2.4
2600 −−− −−− 20.4 11.0 6.5 4.0 2.6
2700 −−− −−− −−− 11.8 6.9 4.3 2.8
2800 −−− −−− −−− 12.7 7.5 4.7 3.1
2900 −−− −−− −−− 13.7 8.0 5.0 3.3
3000 −−− −−− −−− 14.6 8.6 5.4 3.5
3100 −−− −−− −−− 15.6 9.1 5.7 3.7
3200 −−− −−− −−− 16.6 9.7 6.1 4.0
3300 −−− −−− −−− 17.7 10.4 6.5 4.2
3400 −−− −−− −−− 18.8 11.0 6.9 4.5
3500 −−− −−− −−− 19.9 11.7 7.3 4.8
3600 −−− −−− −−− 21.0 12.3 7.7 5.0
3700 −−− −−− −−− 22.2 13.0 8.1 5.3
3800 −−− −−− −−− −−− 13.7 8.6 5.6
3900 −−− −−− −−− −−− 14.5 9.0 5.9
4000 −−− −−− −−− −−− 15.2 9.5 6.2
4100 −−− −−− −−− −−− 15.9 10.0 6.5
4200 −−− −−− −−− −−− 16.6 10.5 6.8
4300 −−− −−− −−− −−− 17.4 11.0 7.1
4400 −−− −−− −−− −−− 18.1 11.4 7.3
4500 −−− −−− −−− −−− 18.8 11.9 7.6
4600 −−− −−− −−− −−− 19.5 12.3 7.9
* For engine values, see technical data in the appendix
Engine and gearbox installation planning
57
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
58
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
NOTE
Component damage due to force acting on the turbocharger
Therefore:
S Exhaust gas lines must be secured and supported so that no forces act upon the turbocharger.
The securing of the exhaust gas system depends on the basic design and concept:
59
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
60
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
NOTE
Turbocharger damage due to exceeding the maximum permissible turbocharger speed
Therefore:
S Low pressure at the exhaust outlet leads to impermissible high turbocharger rpm and is therefore not
allowed.
If the exhaust outlet is located below the water line, incorporate a bypass to the exhaust pipe with an outlet
above the water line.
If this bypass is omitted, there can be a build-up of pressure in the exhaust system when the ship is station
ary or moving at low speed until this pressure exceeds the water pressure below the ship and then escapes
abruptly, resulting in intense vibrations.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
DANGER
Fire hazard due to hot surfaces coming into contact with diesel fuel and oil!
Risk of burns due to hot surfaces.
Therefore:
S Thoroughly insulate exhaust pipes with fireproof material.
NOTE
Component damage due to exceeding the maximum permissible temperature of the electronic
components in the E-box.
Therefore:
S Do not let the engine room temperature exceed 60_C.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
NOTE
Engine damage due to thermal overload
Impermissibly high exhaust gas temperatures lead to inadequate engine power, an increase in smoke
and, consequently, engine damage caused by thermal overload.
Therefore:
S The exhaust backpressure must be measured during commissioning.
S Permissible exhaust back pressure at full load and rated rpm: 20-80 mbar.
63
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Exhaust system
64
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
12 Cooling system
65
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
66
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
Sea valve
Ball valves that are directly connected to the scoop
should be used as sea valves (1). 1
These can be swiftly closed in an emergency (pipe
break).
Furthermore, the valve's “open/closed" position is
immediately recognisable by the position of the
handle.
Seawater filter
A seawater filter is to be provided to protect the
intercooler, heat exchanger and seawater pump.
The seawater filter (2) should be equipped with a
sight glass, a removable cover and a removable
filter basket.
The following approximate values apply to the filter
basket: 2
- Mesh size max. 3 mm
- Surface approx. 10 times as large as the
inlet cross-section
Positioning of sea water filter:
If possible directly above the sea valve.
In any event the sea water filter must be situated
above the water level.
This allows the filter to be cleaned with the sea
valve open. Furthermore, with the sea valve open,
objects blocking the scoops can be removed
without having to lift the ship out of the water.
Seawater pipes to and from engine
The sea water lines (hoses) must be sufficiently
flexible to compensate movements of the engine
due to its resilient mounting.
67
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
68
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
69
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
70
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
Keel cooling
With a keel cooling system, the heat from the engine and intercooling circuit is dissipated to the river or sea
water through pipelines attached on the outside of the hull.
71
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
Engine
(9) Intercooler
(10) Engine crankcase
72
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
73
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
74
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
NOTE
Engine damage due to cooling system malfunction
Therefore:
S Observe the following information regarding the cooling system components.
75
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
(1) Filler neck with pressure valve (7) Connection for filler pipe to coolant pump
(2) Overflow (8) Sensor for monitoring the coolant level
(3) Sensor for monitoring the system pressure The measures A, B, C define volumes:
(4) Pressure valve for restoring the system (A)Air volume
pressure after opening the cooling system with (B)Volume of coolant loss until tripping of alarm, <
the engine at operating temperature 8% of entire system volume
(5) Connection for vent line from engine/intercooler (C)Overall volume of expansion tank
(6) Baffle for air separation
Low-temperature High-temperature
circuit circuit
Tolerances min. max. min. max.
A Air volume in expansion tank % 8 4 11 7.5
C Overall volume of expansion tank % 12 16 11.5 15
Volume of coolant in engine, cooling system and pipes % 80 80 77.5 77.5
Total system volume = volume of coolant in engine, % 100 100 100 100
cooling system, expansion tank and pipes
76
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
Baffles (1)
S steady the flow,
S improve air separation,
S improve the tank strength.
77
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
78
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
79
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
NOTE
Corrosion on aluminium components
Therefore:
S Copper coolant pipes must always be avoided as they can lead to increased corrosion on aluminium
components.
13.3.4 Coolant
The engine cooling system must be filled with a mixture of potable tap water and antifreeze based on ethyl
ene glycol or corrosion inhibitor.
For coolant preparation, see the publication "Fuels, Lubricants and Fluids for MAN industrial and marine
diesel engines".
NOTE
No liability for material damage if non-approved fuels, lubricants and fluids are used!
If non-approved fuels, lubricants and fluids are used, MAN accepts no liability for material damage.
Therefore:
S Only use approved fuels, lubricants and coolants (see “Fuels, lubricants and coolants for MAN indus
trial and marine diesel engines"). A current list of approved products is available online at:
www.asp.mantruckandbus.com
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
13.4.1 General
The shipyard is responsible for the thermodynamic configuration of the cooling system.
NOTE
Cooling system malfunction due to inadequate dimensioning
The monitoring system trips an alarm if the maximum permissible temperatures for the combustion air
downstream of the intercooler or the engine coolant are exceeded.
Therefore:
S Observe the following information regarding the cooling system configuration.
The cooling system must reliably dissipate the heat quantities in the high- and low-temperature circuit to
the seawater.
The functioning of the cooling system is determined by the following parameters:
a) Heat quantities to be dissipated (cooling loads), determined by the engine
b) Coolant circulation
c) Temperature differential between feed and return
d) Pressure differential between feed and return
Parameters 2, 3 and 4 are interlinked. If the pressure loss in the cooling system (= pressure differential bet
ween feed and return) is increased due to the design, the coolant circulation is reduced, leading to an incre
ase in the temperature differential between feed and return.
Diagram
81
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
Engine models Engine power Rated speed Heat quantity to Coolant circula Max. pressure
D2868 LE4.. be dissipated tion in high-tem differential bet
(cooling load) in perature circuit ween feed and
high-temperat return Dp
ure circuit
kW rpm kW litres/min mbar
D2868 LE421 441 1800 300 600 600
D2868 LE422 588 2100 410 800 800
D2868 LE424 441 1800 315 600 600
D2868 LE425 588 2100 425 800 800
D2868 LE431 500 1800 350 600 600
Engine models Engine power Rated speed Heat quantity to Coolant circula Max. pressure
D2862 LE4.. be dissipated tion in high-tem differential bet
(cooling load) in perature circuit ween feed and
high-temperat return Dp
ure circuit
kW rpm kW litres/min mbar
D2862 LE421 662 1800 410 1000 600
D2862 LE422 749 2100 500 1200 800
D2862 LE424 662 1800 410 1000 600
D2862 LE425 749 2100 520 1200 800
D2862 LE431 551 1800 350 1000 600
D2862 LE432 882 2100 580 1200 800
D2862 LE434 551 1800 360 1000 600
D2862 LE435 882 2100 570 1200 800
D2862 LE441 735 1800 480 1000 600
D2862 LE444 735 1800 500 1000 600
D2862 LE463 1029 2100 680 1200 800
D2862 LE466 1029 2100 680 1200 800
82
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
Engine models Engine power Rated speed Heat quantity to Coolant circula Max. pressure
D2868 LE4.. be dissipated tion in low-tem differential bet
(cooling load) in perature circuit ween feed and
low-temperat return Dp
ure circuit
kW rpm kW litres/min mbar
D2868 LE421 441 1800 90 500 800
D2868 LE422 588 2100 120 600 800
D2868 LE424 441 1800 95 500 800
D2868 LE425 588 2100 125 600 800
D2868 LE431 500 1800 100 500 800
Engine models Engine power Rated speed Heat quantity to Coolant circula Max. pressure
D2862 LE4.. be dissipated tion in low-tem differential bet
(cooling load) in perature circuit ween feed and
low-temperat return Dp
ure circuit
kW rpm kW litres/min mbar
D2862 LE421 662 1800 165 500 800
D2862 LE422 749 2100 155 600 800
D2862 LE424 662 1800 165 500 800
D2862 LE425 749 2100 160 600 800
D2862 LE431 551 1800 135 500 800
D2862 LE432 882 2100 170 600 800
D2862 LE434 551 1800 135 500 800
D2862 LE435 882 2100 165 600 800
D2862 LE441 735 1800 150 500 800
D2862 LE444 735 1800 155 500 800
D2862 LE463 1029 2100 190 600 800
D2862 LE466 1029 2100 185 600 800
83
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Ship-side cooling systems
84
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Fuel system
14 Fuel system
85
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Fuel system
NOTE
Engine damage due to water in the fuel.
Water in the fuel causes:
S Incorrect combustion
S Injection system damage
S Piston damage
S Irreparable engine damage
Therefore:
S Install the fuel pre-filter with water separator (MAN scope of delivery).
86
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Fuel system
NOTE
Long fuel lines and numerous elbows cause pressure loss in the
fuel system.
The permitted low pressure of max. 0.35 bar upstream of the fuel pre-filter must not be exceeded even
when the filters are contaminated.
Therefore:
S Attach the fuel pre-filter near the engine.
87
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Fuel system
NOTE
Exceeding the permissible fuel pressures leads to fuel shortage.
Therefore:
S The engine monitoring system trips an alarm if the permissible fuel pressures are not reached or are
exceeded.
88
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
15 Propeller system
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
89
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
Power in %
50
40
30
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
Systems with jet drive must also be configured as per this table.
90
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
Power in %
(3) Reduction curve
(4) Operating point if propeller is too large 50
3
40
30
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
100
Power consumption of propeller too small
The propeller cannot absorb and transfer the avail 90
able engine power. Here the engine speed is much
higher than the rated rpm (operating point 4). 80
30
2
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
91
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
3
Relative load
Speed in %
User tip
This is calculated at a certain rpm delivered torque from the diesel injection quantity.
The relative value is determined by comparing with the maximum possible injection quantity correspond
ing to 100 % (this is stored in the control unit data record).
92
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
93
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
Speed in %
(1) Acceleration
S Brief operation for increasing the load by increasing the rpm
S Speed lower than 100% of rated rpm
S If there is prolonged operation with overload, a warning is output via the MMDS
S Continuous operation is allowed for heavy operating mode
S Continuous operation is not allowed for medium and light operating modes
(2) Normal operation
S Continuous operation allowed, limit rpm 100 to 102% of rated rpm
(3) "As new" condition
S Operating range for new, fully laden ship
S Continuous operation allowed, limit rpm 102 to 104% of rated rpm
(4) Low load
S Operating range for relatively high rpm and low loads
S Continuous operation allowed but inefficient
94
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
NOTE
The ship's speed must be controlled by the engine speed and not by the propeller pitch.
Therefore:
S Always equip the controllable pitch propeller system with a load control system.
95
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Propeller system
Engines with rated speed 2100 rpm Engines with rated speed 1800 rpm
(medium duty) (heavy duty)
Speed (rpm) Relative load (%) Speed (rpm) Relative load (%)
2150 100 1850 100
2100 87.0 1800 85.0
2000 70.0 1700 67.0
1900 58.0 1600 55.0
1800 49.0 1500 45.0
1700 41.0 1400 36.0
1600 33.0 1300 28.3
1500 27.4 1200 22.2
1400 22.2 1100 16.5
1300 17.2 1000 12.7
1200 13.3 900 11.1
1100 11.4 800 10.4
1000 10.7 700 10.2
900 10.3 600 10.0
800 10.2
700 10.1
600 10.0
96
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cabin heater
16 Cabin heater
97
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cabin heater
98
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Power take-off and hydraulic pumps
99
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Power take-off and hydraulic pumps
100
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electrical system
18 Electrical system
18.1.1 Starter
101
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electrical system
102
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electrical system
18.2 Generators
Engine models V8 / V 12
Generator type Bosch
Rated voltage 24 V
Rated current 120 A
- Undervoltage
- Overvoltage L 15
- Discontinuity at terminal 15
B− B+
G
3
− Batt.
+ Batt.
103
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electrical system
Coolant pre-heater
System Calix 1100 W / 230 V
One pre-heater (1) is factory fitted on each side of
the engine - on the side of the engine below the
exhaust pipe.
Retrofitting is only possible in some cases due to
accessibility.
104
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electronic box
105
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electronic box
106
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electronic box
NOTE
False alarms due to missing or defective earthing of the E-box
Therefore:
S Connect the E-box ground connection to the ship's potential and the engine block.
A diagram for the wiring of the E-box to the ship's potential can be found in the appendix to this manual
from page 213 under "Potential-free wiring of the basic components".
107
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Electronic box
108
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
Design and equipment of the internal throttle lever control system MPC
- Rpm control (electrical 4-20 mA)
- Rpm synchronisation possible
- Trolling possible
- Gearbox control (electrical digital)
109
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
NOTE
Incorrect wiring of the throttle lever control system and the throttle lever leads to data commu
nication malfunctions
Therefore:
S Connect the CAN bus as specified.
110
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
PIN Socket
L 40
111
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
Terminating resistors
The Bosch Rexroth throttle levers communicate with the throttle lever control system in the E-box in the en
gine room via a CAN bus. This CAN bus must always have a termination resistor at the start and end.
Terminator at start of bus in engine terminal box
The controller in the engine room has an internal terminating resistor (dip switch S1) on the mother board
which does not have to be set. Default setting: S1 set to the right.
S1: Switch, termination resistor, throttle lever
S2: Switch, termination resistor, cross-communication
NOTE
Malfunctions due to redundancy
The cross-communication CAN‐terminator is realised by the DIP‐switch S2 at "ON" on both sides. Only
in the case of systems with more than 2 engines must the DIP switch S2 for control of the centre en
gines be switched to "OFF".
Therefore:
S No termination resistor must be connected to any of the open connectors X13 (e.g. starboard) / X14
(e.g. port). Plug open connectors with caps.
112
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
113
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
In order to achieve the same ground potential in the case of control via voltage outputs 24V, the voltage for
the external throttle lever control system must be supplied via X4 / pin 12 and pin 13.
The external throttle lever control system must be "earthed" to the ship's potential.
114
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
Throttle lever control system voltage supply via ignition (tI. 15 / 31)
It is recommended to connect the throttle lever control system supply voltage to pin 12 (15+)
and pin 13 (31-) (max. 8 A) via the shipyard connection X4 (see figure on page 122).
This ensures that the throttle lever control system is also switched off when the ignition is switched off.
There is then no undesirable battery discharge.
Throttle lever control system voltage supply via battery (tI. 30 / 31)
When connecting the throttle lever control systems to the battery voltage, observe the safety measures
specified by the manufacturer.
If the current consumption of the throttle lever control system is max. 3 A in the continuous operating state,
terminals 30 (Bat+), 31 (Bat-) in shipyard connector X4 (see chapter 24) can be used for this.
For connection to this, see diagram on page 122, connector X4 pin 1 (31-) and pin 2 (30+).
Only use the battery belonging to the engine for connecting the voltage supply.
NOTE
Battery discharge and resulting starting problems
Therefore:
S Disconnect the external throttle lever control system from the battery using the master switch if the
ship is to be left for longer periods (several days).
115
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
116
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
+ - - + Connector X9
E-box
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector A for + -
throttle lever for - +
electrical
rpm‐ Jumper for Input 4-20 mA for
engine control
output external engine control
EDC throttle
8 lever con
trol system
7
6 Rout 300
5 Umax 15V (at idle speed
4 Imax 48 mA (if short-circuit)
3 fmax 800 Hz (at 8000 rpm)
Duty cycle 50% (Symetic signal)
2
1
0
0 2 4 6 8 10 12 14
0-8000 rpm 0-800 Hz
rpm signal (Out) 14V
(RL = 8 kW)
Duty cycle 50%
tmax = 500 ms
117
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Throttle lever control system
118
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Emergency unit
21 Emergency unit
Technical data
119
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Emergency unit
(1) E-box
(2) Emergency unit
(3) Connecting cable
The emergency unit is connected at E-box connector X6 or integrated into the existing CAN bus, also see
appendix to this manual from page 213 under "System overview - CAN bus system".
Connecting cable
Emergency unit E-box
Socket PIN
L 40
120
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Yard-side wiring connection
121
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Yard-side wiring connection
122
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Yard-side wiring connection
123
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Yard-side wiring connection
+24 V
+24 V 1
2 2
2 3 Start Eng.
3
Start Eng. 1
2
Ign. Out
3 3 4
ON OFF ON OFF
16 16
Ign. In Ign. In
DIP‐Switch on Motherboard S4
124
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Yard-side wiring connection
18 k
Emergency stop 1 Emergency stop 2
6
125
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Yard-side wiring connection
X4
10 HORN
Floating
contact MMDS + -
11
External voltage supply
126
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Display systems and instruments
127
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Display systems and instruments
There is a choice of seven languages to enhance ease of use: English, German, Italian, French, Spanish,
traditional Chinese and simplified Chinese. The data can be displayed using either metric or non-metric
units of measurement.
The front side of the display is categorised as protection class IP 67 and is therefore sufficiently watertight
to be used even on open bridges. A UV-resistant plastic film across the entire front protects the device and
the controls from environmental influences and dirt. The display unit's front panel has an integral photoele
ment which detect the ambient brightness and adjusts the background illumination automatically to suit the
conditions. If the ambient light decreases, the display brightness is reduced. If the ambient light increases,
the display brightness is increased. The brightness level of the automatic dimming can be adapted to indi
vidual requirements on the device. The transreflective display ensures that the data remain as legible as
possible in direct sunlight.
To supplement the system, an outwardly identical display for showing ship data is available. It can display
fuel level, range and many other values via a further CANbus.
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Display systems and instruments
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Display systems and instruments
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Display systems and instruments
23.4.1 Wiring for colour display MMDS-CLC 6.5 and MMDS-CLC 8.8
Connecting cable
CLC 6.5 display E-box or CLC 6.5 display T-piece
Socket PIN
L 40
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Display systems and instruments
T-piece (1)
MAN part no. 51.25433-0023
Adapter for connecting additional VDO circular gauges (MAN part no. 51.25411-6014)
A
G A
P H
B C
5
4 3
1 2
1 2 3
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Engine Operation Panel
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Engine Operation Panels
Technical data
General data
Dimensions, W x H x D: 70 x 130 x 65 mm
Console cut-out, W x H: 60 x 113 mm
Weight: approx. 0.5 kg
Ambient data
Operating temperature: -25 °C ... +70 °C
Storage temperature: -30 °C ... +85 °C
Degree of protection: IP 67 (front side), IP 65 (rear side)
Electrical data
Voltage supply: 9 ... 32 VDC
Power/current consumption: max. 400 mA
Interfaces on cable side: 2x M12 round plug connections (socket, 8-pin)
Ignition enable on cable side: 1 floating relay contact, NO, 24 V DC/8A
(IGN-FREE)
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Engine Operation Panel
Technical data
General data
Dimensions, W x H x D: 70 x 130 x 65 mm
Console cut-out, W x H: 60 x 113 mm
Weight: approx. 0.5 kg
Ambient data
Operating temperature: -25 °C ... +70 °C
Storage temperature: -30 °C ... +85 °C
Degree of protection: IP 67 (front side), IP 65 (rear side)
Electrical data
Voltage supply: 9 ... 32 VDC
Power/current consumption: max. 400 mA
Interfaces on cable side: 2x M12 round plug connections (socket, 8-pin) to EOP
2x M12 round plug connections (socket, 8-pin) to EOP D
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Engine Operation Panels
24.3 Connecting cable for Engine Operation Panels EOP and EOP D
Engine Operation Panel EOP E-box and EOP EOP D
14.5
L 40
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Override system
25 Override system
NOTE
Danger of engine damage if alarms are ignored.
Therefore:
S The override system is only allowed to be used in emergencies. Remedy the cause of an alarm.
MAN accepts no liability for engine damage caused by the use of the override system.
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Override system
Connecting cable
Override button E-box
40 L 40
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Assembly
Assembly
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Assembly
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Safety instructions for assembly and commissioning
26.2.1 Qualifications
WARNING
Risk of injury due to insufficient qualifications
Incorrect handling can lead to serious injury or damage.
Therefore:
S Make sure that the special work steps or activities described are only performed by personnel named
in the particular chapters of this manual.
The following qualifications for various areas of activity are named in the Operator's Manual:
S Trained person
has been trained in the tasks assigned to them and informed of possible dangers in the event of incor
rect actions.
S Qualified personnel
are able to perform the tasks assigned to them correctly based on their technical training, knowledge
and experience as well as their awareness of the relevant requirements and regulations.
S Electrical expert
is able to perform work on electrical systems and independently detect and prevent possible dangers
based on their technical training, knowledge and experience as well as their awareness of the relevant
standards, regulations and requirements.
The electrical expert is trained for the specific operating site at which they work and is fully aware of the
relevant standards, regulations and requirements.
Personnel must be people who can be expected to perform their work reliably. People whose reactions are
affected by drugs, alcohol or medication are not allowed to be used as personnel.
S Observe the age and job-related requirements applicable at the operating location when selecting per
sonnel.
WARNING
Unauthorised persons
Unauthorised persons who do not meet the requirements described here are not aware of the dangers
in the working area.
Therefore:
S Keep unauthorised persons well away from the working area.
S In case of doubt, approach a person and direct them out of the working area.
S Stop work if there are any unauthorised persons in the working area.
Protective workwear
is tight-fitting work clothing that tears easily, with tight-fitting sleeves and no hanging
parts. It is mainly designed to protect against injury, climate conditions and dirt/contam
ination.
Do not wear rings, chains or any other jewellery whilst working.
Hard hat
to protect against falling or flying parts.
Safety gloves
to protect the hands against friction, grazing, stabbing, cuts or contact with hot or cor
rosive parts or liquids
Protective goggles
to protect the eyes against flying parts or sprayed liquids.
Ear protectors
to protect against hearing damage caused by noise.
Electrical current
DANGER
Danger to life due to electrical current
Immediate danger to life upon contact with live components.
Damaged insulation or component parts can put lives at risk.
Therefore:
S If insulation is damaged, shut off the voltage supply immediately and arrange to have it repaired.
S Only have work on the electrical system performed by electrical experts.
S Switch off the electrical system and ensure that it is fully de-energised before performing
any work on it.
S Switch off the voltage supply and ensure that it cannot be switched back on again inadvertently before
performing any maintenance, cleaning or repair work.
S Do not short-circuit or deactivate any fuses. When changing fuses, make sure the new fuses have the
correct amp rating.
S Keep moisture away from live components, as this can cause short-circuits.
Moving components
DANGER
Danger to life due to rotating machine parts
Therefore:
S For safety reasons, rotating machine parts (shafts, flanges) must be equipped with suitable accidental-
contact protection. Observe accident prevention regulations!
WARNING
Fire hazard due to highly inflammable substances
Highly inflammable substances, liquids or gases can catch fire and cause serious injury or death.
Therefore:
S Do not smoke within or near the danger area.
Ensure that there are no naked flames or sources of ignition.
S Keep fire extinguishers nearby.
S Report any suspicious substances, liquids or gases to the person in charge immediately.
S In case of fire, stop work immediately and leave the danger area until the all-clear is given.
WARNING
Risk of injury due to coolant that is hazardous to health
Coolant contains substances that are hazardous to health. Contact with these substances can lead to
serious intoxication, allergies, skin irritation and eye damage.
Therefore:
S Observe the manufacturers' safety information.
S When handling coolants, always wear protective workwear, chemical-resistant gloves and protective
goggles.
S Avoid spillage and fog formation.
WARNING
Risk of burns due to hot fuels, lubricants and fluids
Fuels, lubricants and fluids can reach high temperatures during operation and cause burns upon contact
with the skin.
Therefore:
S Before handling fuels, lubricants or fluids, check whether they are hot and let them cool down if neces
sary.
Hot surfaces
CAUTION
Risk of burns due to hot surfaces
Contact with hot components can cause burns.
Therefore:
S Always wear protective workwear and protective gloves whenever working near hot components.
S Ensure that all components have cooled down to the ambient temperature before commencing work.
Noise
WARNING
Hearing damage due to noise
The noise level in the working area can cause serious hearing damage.
Therefore:
S Always wear ear protectors whenever carrying out work.
S Only remain in the danger area for as long as necessary.
CAUTION
Risk of injury on sharp edges and corners
Sharp edges and corners can cause skin grazes and cuts.
Therefore:
S Always proceed with caution when working near sharp edges and corners.
S Wear protective gloves if in doubt.
CAUTION
Risk of tripping due to dirt and objects lying around
Dirt and objects lying around can cause slipping and skidding, which can lead to serious injuries.
Therefore:
S Keep the working area clean at all times.
S Remove objects that are no longer needed.
S Mark tripping hazards with yellow/black marking tape.
NOTE
Risk of damage due to incorrect handling of welding equipment
Component and electronic damage due to electric arc welding
Therefore:
S Connect the „ANTIZAP SERVICE SENTRY“ protection device (MAN part number 80.78010-0002)
as described in the instructions accompanying the device.
S If this device is not available, disconnect the batteries and connect the positive cable
to the negative cable in order to make a permanent conductive connection.
S Manually operated battery master switch in driving position.
If an electronic battery master switch is fitted, bridge „Negative“ at the load-disconnecting relay con
tacts (jumper cable > 1mm2) and „Positive“ at the load-disconnecting relay load contacts. Also switch
on as many load consumers as possible, e.g. starter switch (ignition) in driving position. The greater
number of consumers that are switched on, the greater the protection..
After completing welding work, first switch off all the consumers
and remove all jumpers (re-create original state), then connect the batteries.
S Always earth the welding equipment as close as possible to the welding area.
Do not lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
WARNING
Danger to life due to non-functioning safety equipment
Safety equipment ensures maximum safety during operation. Even if safety equipment makes working
more inconvenient, it must never be disabled. Safety can only be assured if the safety equipment is in
tact.
Therefore:
S Check that all safety equipment is working and installed correctly before commencing work.
S Check that all safety equipment is working and installed correctly before starting the engine.
Preventive measures
S Always be prepared for accidents or fires!
S Keep first-aid equipment (first-aid kit, blankets etc.) and fire extinguishers close to hand.
S Regularly check to ensure that first-aid equipment is complete and that fire extinguishers work correctly.
S Instruct personnel in the use of accident-reporting, first-aid and rescue equipment.
S Hold regular safety training sessions.
S Keep access routes for rescue vehicles clear.
CAUTION
Accident despite taking every precautionary measure
An accident may occur despite having taken all the precautionary measures, e.g. due to the reasons
listed below.
Therefore, always seek medical assistance in the event of:
S Contact with corrosive acid.
S Fuel getting into the skin.
S Scalding by hot oil or coolant.
S Antifreeze spraying into the eyes etc..
WARNING
Risk of injury due to illegible symbols
Over the course of time, labels and symbols can get dirty or become illegible in some other way!
Therefore:
S Ensure that all safety, warning and operating notices remain easily legible at all times.
S Clean or replace illegible safety, warning and operating notices
Access forbidden
Access to areas displaying this sign is forbidden.
Electrical voltage
Only electrical experts are allowed to work in areas displaying this sign.
Unauthorised persons are not allowed to enter areas displaying this sign.
Hot surfaces
Hot surfaces such as hot engines and hot fluids are not always discernible. Do not touch
these surfaces without wearing protective gloves.
Risk of injury
Risk of injury if the instructions in the Operator's Manual are not followed.
CAUTION
Environmental hazard due to incorrect handling
Incorrect handling of environmentally hazardous substances, especially incorrect disposal, can cause
serious damage to the environment.
Therefore:
S Always follow the instructions below.
S Take suitable action immediately if environmentally hazardous substances are released into the envir
onment inadvertently. In case of doubt, inform the relevant municipal authorities of the pollution.
Lubricants
Lubricants such as greases and oils contain toxic and environmentally hazardous substances. They must
not get into the environment and must be disposed of by a specialist disposal company.
Diesel fuel
Diesel contains toxic and environmentally hazardous substances. They must not get into the environment
and must be disposed of by a specialist disposal company.
Coolant
Coolants contain toxic and environmentally hazardous substances. They must not get into the
environment and must be disposed of by a specialist disposal company.
DANGER
Falling loads (weighing up to 3000 kg!) can lead to serious accidents!
Therefore:
S Use adequately dimensioned crane lifting tackle to lift an engine!
Ropes, cables and chains must not pull diagonally on the crane hook!
Crane lifting tackle, ropes, cables and chains must be in good working order.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Crane transport of a drive line
For lifting the engine, 4 crane hook lugs (3) are mounted on the engine.
Use sufficiently dimensioned crane lifting gear (1) to lift the engine!
Cables, ropes and chains (2) must exert vertical tension (tolerance 5_) on the crane hooks!
DANGER
Falling loads (weighing up to 2500 kg!) can lead to serious accidents!
Therefore:
S Use crane lifting gear to lift the engine!
The crane lifting gear, cables, ropes and chains must be in perfect condition.
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Crane transport of a drive line
For lifting the engine with gearbox, there are 2 crane hook lugs mounted on the gearbox (4) and 2 crane
hook lugs mounted on the engine (3).
Use sufficiently dimensioned crane lifting gear (1) to lift the engine!
Cables, ropes and chains (2) must exert vertical tension (tolerance 5_) on the crane hooks!
DANGER
Falling loads (weighing up to 3500 kg!) can lead to serious accidents!
Therefore:
S Use crane lifting gear to lift the engine!
The crane lifting gear, cables, ropes and chains must be in perfect condition.
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Crane transport of a drive line
NOTE
The smallest particles of dirt in the fuel system can lead to total failure of the injection system
Therefore:
S Ensure the utmost cleanliness when working in the engine room.
S Fuel connections must be plugged with caps.
NOTE
Moisture in the fuel system can lead to total failure of the injection system
The engine will be delivered ex works with the fuel system plugged with caps (feed and return lines).
Therefore:
S Do not unplug fuel connections before commissioning
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Mounting the gearbox
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Mounting the gearbox
NOTE
Engine damage due to missing crankshaft axial clearance
Therefore:
S The designed crankshaft axial clearance of the engines must not in any event be reduced by the
flange-mounting of couplings or other components.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Installing the resilient engine and gearbox mounts
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Installing the resilient engine and gearbox mounts
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Aligning drive line
NOTE
Damage due to vibrations and oscillations
Therefore:
S Check the alignment of the drive line every year or after around 3000 operating hours, then correct as
necessary.
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Aligning drive line
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Aligning drive line
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Aligning drive line
30.1.4 Checking the gearbox output and propeller shaft for radial offset
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Aligning drive line
30.1.5 Checking the gearbox output and propeller shaft for angle offset
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Aligning drive line
Auxiliary equipment consisting of two alignment rods can be used to obtain the same working angle for a
Vconfiguration.
Such auxiliary equipment is illustrated below.
For the dimensions given this equipment can be used for propeller shafts with lengths of
Lz = 700 to 1300 mm. Shorter or longer propeller shafts require shorter or longer rods A.
Procedure: Mount alignment rods in place of the propeller shaft. Both parts must be of the same length.
Align engine or gear box so that the tips of the alignment rods meet. Remove the auxiliary equipment and
mount the propeller shafts.
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Assembling propeller shafts
NOTE
Vibrations in the power train - Damage on spherical plain bearings and splines
Incorrectly attached propeller shafts increase rather than balance the irregularity at the output.
Therefore:
S Assemble the propeller shafts as indicated by the manufacturer.
When putting together the propeller shaft halves, ensure that the markings on the splined shaft and splined
hub (arrows) are opposite each other.
Arrange the propeller shafts so that the spline is as well protected against dirt and moisture as possible.
Generally this means installing as per the diagram below, where the profile seal points downwards so that
any dripping spray flows away from the spline.
The propeller shafts must not be separated at the splined section and must not be swapped with each
other. Otherwise the balance of the shafts will be considerably affected. For this reason the balance
weights are also not to be removed.
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Assembling propeller shafts
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Connecting the fuel lines
NOTE
The smallest particles of dirt in the fuel system can lead to total failure of the injection system.
Therefore:
S Always maintain conditions of absolute cleanliness when working on the fuel system.
S Fuel connections must be plugged with caps.
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Connecting the fuel lines
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Installation of exhaust pipe bellows
NOTE
Foreign bodies and dirt in the engine will result in damage
Therefore:
S Do not allow any foreign bodies (screws, washers etc.) to fall into the engine when working on the ex
haust gas system
S Cover the engine with a tarpaulin before cutting or grinding metal
NOTE
Risk of damage due to incorrect handling of welding equipment
Component and electronic damage due to electric arc welding
Therefore:
S Connect the ANTIZAP SERVICE SENTRY protection device (MAN part number 80.78010-0002)
as described in the instructions accompanying the device.
S If this device is not available, disconnect the batteries and connect the positive cable
to the negative cable in order to make a permanent conductive connection.
S Manually operated battery master switch in driving position.
If an electronic battery master switch is fitted, bridge Negative at the load-disconnecting relay contacts
(jumper cable > 1mm2) and Positive at the load-disconnecting relay load contacts. Also switch on as
many load consumers as possible, e.g. starter switch (ignition) in driving position, hazard warning
lights on light switch in driving lights on position, ventilation blower at maximum setting. The greater
number of consumers that are switched on, the greater the protection.
After completing welding work, first switch off all the consumers
and remove all jumpers (re-create original state), then connect the batteries.
S Always earth the welding equipment as close as possible to the welding area.
Do not lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
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Installation of exhaust pipe bellows
3 3
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Installation of exhaust pipe bellows
NOTE
Component damage due to horizontal installation
Therefore:
S Install the exhaust pipe bellows as vertically as possible and support the continuing exhaust pipe secu
rely.
S Pay attention to the direction of flow of the exhaust gas through the exhaust pipe bellow.
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Installation of exhaust pipe bellows
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Torques for threaded connections
Bolts/nuts with hexagon head‐ or hexagon socket, head without collar or flange
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Torques for threaded connections
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Assembly drawings
35 Assembly drawings
35.1 E-box
346-348
382-383
E-box assembly
S Secure the E-box vertically on a side wall in the engine room
S M8 mounting bolts
S E-box weight: 8 kg
Free space of 200 mm must be left around the E-box for the connectors.
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Assembly drawings
420.3
501
701
800.3
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Assembly drawings
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Assembly drawings
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Assembly drawings
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Assembly drawings
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Assembly drawings
3.2-3.4
24.1-24.5
49
48
22.3-22.7
40 10 10
57 30
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Assembly drawings
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Preparations for commissioning
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Preparations for commissioning
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Important notes on commissioning
NOTE
Incorrectly performed initial 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).
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Important notes on commissioning
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Lube oil system
NOTE
No liability for material damage if non-approved fuels, lubricants and fluids are used!
If non-approved fuels, lubricants and fluids are used, MAN accepts no liability for material damage.
Therefore:
S Only use approved fuels, lubricants and fluids (see publication “Fluids, Lubricants and Coolants for
MAN Industrial and Marine Diesel Engines"). A current list of approved products can be found online
at: www.asp.mantruckandbus.com
NOTE
Component damage due to overfilling
Engine damage can occur if the max. permissible oil fill quantity is exceeded.
Therefore:
S Determine the fill quantity of the oil pan mounted on the engine. For oil pan oil fill quantity, see follow
ing table or label on a valve cover.
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Lube oil system
NOTE
Engine damage due to dirt in the engine oil.
Therefore:
S Ensure absolute cleanliness when filling with engine oil.
ENVIRONMENTAL NOTE
Do not spill engine oil during filling. Do not allow engine oil to leak into the ground or into watercourses.
The engines can be equipped with marked or non-marked oil dipsticks, depending on the installation situ
ation.
If the oil dipsticks are not marked ex factory, they must be marked when the engine is first filled with engine
oil, see page 189.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Lube oil system
NOTE
Incorrectly marked oil dipsticks lead to an incorrect oil fill and can make the engine a total
write-off.
Therefore:
S The oil dipsticks are to be marked solely by personnel authorised by MAN Nuremberg Marine Engines
department.
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Lube oil system
37.3.3 Electrical oil change pump for engine and gear oil
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Lube oil system
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Lube oil system
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
38 Cooling system
The engine cooling system must be filled with a mixture of potable tap water and antifreeze based on ethyl
ene glycol or corrosion inhibitor.
For coolant preparation, see the publication "Fuels, Lubricants and Fluids for MAN industrial and marine
diesel engines".
ENVIRONMENTAL NOTE
Do not spill coolant during filling. Do not allow coolant to leak into the ground or into watercourses.
The bleed screws (1) and (2) are below the coolant
level in the expansion tank (4).
1. Undo the bleed screws (1) and (2).
2. Slowly pour in coolant at the filler neck on the
expansion tank (3) until coolant emerges from
the bleed screws without bubbles.
3. Screw in the bleed screws (1) and (2) one after
the other, then screw in the cap (3) up to the
stop, but do not tighten it.
Overtightened caps can not be opened again.
4. Leave the engine running at 1200 rpm for
around 15 minutes.
5. Stop the engine.
Continue with Step 13, see page 194.
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
38.3 Opening the cooling system with the engine at operating temperature
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Cooling system
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Starting and stopping the engine
NOTE
Engine damage due to missing fuels, lubricants and fluids
Before starting the engine, ensure that:
S Lube oil is added, see page 187
S Coolant has been added, see page 193
S The seawater pump has been filled with water
DANGER
Fire hazard due to diesel fuel
Diesel fuel is highly inflammable.
Therefore:
S Do not smoke within the danger zone when refuelling.
No naked flames or sources of ignition are permitted.
S Only refuel when the engine is stopped.
S Ensure cleanliness.
S Do not spill any diesel fuel.
ENVIRONMENTAL NOTE
Do not spill any diesel during filling. Do not allow diesel fuel to leak into the ground or into watercourses.
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Starting and stopping the engine
NOTE
Non-compliance with the stopping procedure leads to fault entries in the fault memory
(EDC / SFFR / MMDS) and can lead to a reduction in the engine speed.
Therefore:
S Switching off the EDC‐engine control voltage supply with the battery master switch is not permissible
when the ignition is switched on.
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Technical data
Technical data
Technical data
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data
Technical data
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - light duty
Exhaust status IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2 IMO Tier 2
EPA Tier 3 EPA Tier 3 EPA Tier 3 EPA Tier 3 EPA Tier 3 EPA Tier 3 EPA Tier 3
Rated power kW 735 735 882 882 1029 1029 1140 1140 1213 1213 1324 1324 1397
hp 1000 1000 1200 1200 1400 1400 1550 1550 1650 1650 1800 1800 1900
Rated speed rpm 2300 2300 2300 2300 2300 2300 2300 2300 2300 2300 2300 2300 2300
Max. torque Nm 3350 3340 4010 4010 4670 4680 5140 5180 5520 5510 6020 6010 6220
at engine speed rpm 1300- 1300- 1200- 1200- 1200- 1200- 1300- 1200- 1200- 1200- 1200- 1200- 1200-
2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100 2100
Fuel consumption g/ 223 227 220 229 217 218 218 220 218 223 215 223 224
at max. power kWh
Average weight kg 1780 1780 1875 1875 2270 2270 2270 2270 2365 2365 2365 2365 2365
(dry, without gearbox)
Ventilation system
D2868 D2868 D2868 D2868 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862
LE423 LE426 LE433 LE436 LE443 LE446 LE423 LE426 LE453 LE456 LE433 LE436 LE476
V8-1000 V8-1000 V8-1200 V8-1200 V12-1400 V12-1400 V12-1550 V12-1550 V12-1650 V12-1650 V12-1800 V12-1800 V12-1900
Combustion air m3 / h 2870 2910 3800 3820 4470 4255 4550 4340 5260 5210 5300 5360 5470
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MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - light duty
D2868 D2868 D2868 D2868 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862
LE423 LE426 LE433 LE436 LE443 LE446 LE423 LE426 LE453 LE456 LE433 LE436 LE476
V8-1000 V8-1000 V8-1200 V8-1200 V12-1400 V12-1400 V12-1550 V12-1550 V12-1650 V12-1650 V12-1800 V12-1800 V12-1900
Exhaust volume flow rate m3 / h 8250 7960 9450 9600 11600 11020 12200 12400 13070 12900 13620 13600 15850
Exhaust gas temperature _C 565 535 475 475 520 500 558 550 460 470 490 490 590
downstream of turbochar
ger
202
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - light duty
Fuel system
D2868 D2868 D2868 D2868 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862
LE423 LE426 LE433 LE436 LE443 LE446 LE423 LE426 LE453 LE456 LE433 LE436 LE476
V8-1000 V8-1000 V8-1200 V8-1200 V12-1400 V12-1400 V12-1550 V12-1550 V12-1650 V12-1650 V12-1800 V12-1800 V12-1900
Fuel delivery volume l/h 700 700 700 700 700 700 700 700 700 700 700 700 700
Fuel supply low pressure bar 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25 0-0,25
(new filter cartridge)
Fuel supply low pressure bar 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35 0,35
(filter cartridge contamin
ated)
Zero-feed throttle bar t0,2 t0,2 t0,2 t0,2 t0,2 t0,2 t0,2 t0,2 t0,2 t0,2 t0,2 t0,2 t0,2
fuel return pressure
Threaded connector M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2
fuel supply connection
Threaded connector M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2
fuel return connection
203
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - light duty
Cooling system
D2868 D2868 D2868 D2868 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862 D2862
LE423 LE426 LE433 LE436 LE443 LE446 LE423 LE426 LE453 LE456 LE433 LE436 LE476
V8-1000 V8-1000 V8-1200 V8-1200 V12-1400 V12-1400 V12-1550 V12-1550 V12-1650 V12-1650 V12-1800 V12-1800 V12-1900
Pressure downstream of bar -0,3 -0,3 -0,3 -0,3 -0,3 -0,3 -0,3 -0,3 -0,3 -0,3 -0,3 -0,3 -0,3
seawater inlet with ship sta to to to to to to to to to to to to to
tionary and rated rpm 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3
Pressure downstream of bar -0,05 -0,05 -0,05 -0,05 -0,05 -0,05 -0,05 -0,05 -0,05 -0,05 -0,05 -0,05 -0,05
seawater inlet at max. ship to to to to to to to to to to to to to
speed 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3
204
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - medium duty
Rated power kW 588 588 749 749 882 882 1029 1029
hp 800 800 1019 1019 1200 1200 1400 1400
Rated speed rpm 2100 2100 2100 2100 2100 2100 2100 2100
Torque Nm 2950 2980 3780 3770 4450 4450 5120 5180
at engine speed rpm 1300-1900 1400-1900 1300-1900 1100-1900 1300-1900 1400-1900 1300-1900 1300-1900
Fuel consumption g / kWh 212 223 207 215 211 208 210 209
at max. power
Average weight kg 1800 1800 2270 2270 2270 2270 2270 2270
(dry, without gearbox)
Ventilation system
Combustion air m3 / h 2460 2490 3840 3200 3950 3440 4110 3910
Low pressure downstream mbar 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60
of air filter
Filter clean / contaminated
205
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - medium duty
Exhaust volume flow rate m3 / h 5920 6310 8450 7590 9560 8650 10700 10000
Exhaust gas temperature down _C 425 470 375 435 435 475 510 485
stream of turbocharger
Exhaust back pressure min. / max. mbar 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80
Fuel system
Fuel delivery volume l/h 700 700 700 700 700 700 700 700
Fuel supply low pressure bar 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25
(new filter cartridge)
Fuel supply low pressure bar 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
(filter cartridge contaminated)
Zero-feed throttle bar t0.2 t0.2 t0.2 t0.2 t0.2 t0.2 t0.2 t0.2
fuel return pressure
Threaded connector M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2
fuel supply connection
Threaded connector M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2
fuel return connection
206
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - medium duty
Cooling system
207
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - medium duty
208
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - heavy duty
Rated power kW 441 441 500 662 662 551 551 735 735
hp 600 600 680 900 900 749 749 1000 1000
Rated speed rpm 1800 1800 1800 1800 1800 1800 1800 1800 1800
Torque Nm 2630 2630 2985 3955 3950 3305 3305 4380 4380
at engine speed rpm 1100-1600 1100-1600 1100-1600 1100-1600 1100-1600 1000-1600 1000-1600 1100-1600 1100-1600
Fuel consumption g / kWh 206 220 206 198 203 198 204 212 200
at max. power
Average weight kg 1800 1800 1800 2270 2270 2270 2270 2270 2270
(dry, without gearbox)
Ventilation system
Combustion air m3 / h 2100 2145 2070 2825 2910 2600 2700 2960 2900
Low pressure downstream mbar 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60 30 / 60
of air filter
Filter clean / contaminated
Waste heat due to radiation, convection kW 29 29 29 35 35 35 35 35 35
209
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - heavy duty
Exhaust volume flow rate m3 / h 4930 4960 4630 6100 6260 5800 5480 7120 6580
Exhaust gas temperature down _C 380 385 395 355 370 330 335 440 402
stream of turbocharger
Exhaust back pressure min. / max. mbar 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80 20 / 80
Fuel system
Fuel delivery volume l/h 700 700 700 700 700 700 700 700 700
Fuel supply low pressure bar 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25 0-0.25
(new filter cartridge)
Fuel supply low pressure bar 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35
(filter cartridge contaminated)
Zero-feed throttle bar t0.2 t0.2 t0.2 t0.2 t0.2 t0.2 t0.2 t0.2 t0.2
fuel return pressure
Threaded connector M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2
fuel supply connection
Threaded connector M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2 M30x2
fuel return connection
210
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - heavy duty
Cooling system
211
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Technical data - heavy duty
212
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Appendix
Appendix
Wiring diagrams
213
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Appendix
Wiring diagrams
214
System overview - CAN bus system
27
1 2 3 4
17
28
7
5 6
8
10 9 9
X16
11
20 X1
21 X9 9
12
25
22 28
X5
13
19 X4 X15
X13
14
23
X14
18 X6
26
X7 X10 X8
16 15
24
25
8255
215
System overview - CAN bus system
216
Wiring diagram of basic components
Starter Starter
motor Batteries motor Batteries
for starter for starter
motor motor
Batteries Batteries
2nd. Alternator for additional 2nd. Alternator for additional
(optional) onboard (optional) onboard
consumers consumers
E-Box Engine‐ and gearbox brackets E-Box Engine‐ and gearbox brackets
Vessel potential
217
Wiring diagram of basic components
218
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Index
40 Index
40.1 Abbreviations
Index
219
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Index
Index
220
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Index
40.3 Index
A C
Air filter, Low pressure downstream of air filter, 50 Cabin heater, 97
Air intake system Combustion air, 50 Connections, 98
Aligning the drive line, 159 Diagram, 97
Assembly, 139 - 163, 183 - 207, 199 - 223 Thermal output, 98
Assembly drawings Charge check lamp, 126
Display MMDS-CLC 6.5, 177 Cleanliness
Display MMDS-CLC 8.8, 178 Dust protection, 154
E-box, 175 Moisture protection, 154
Emergency unit, 180 Colour display MMDS-CLC, Wiring, 131
Engine Operation Panel - EOP, 179 Colour display MMDS-CLC 6.5
Engine Operation Panel - EOP D, 179 Displays, 128
Override button, 181 Visualisation, 129
Throttle lever control system, 176 Colour display MMDS-CLC 8.8, Displays, 130
Commissioning
Fill coolant, 193
Filling with engine oil, 187
Important notes, 185
Lube oil system, 187
Controllable pitch propeller, Relative load adjust
ment, 96
Coolant, 80
Cooling system
Choice of materials, 70
Diagram, 65
pressurised system, 79
Sea valve, 67
Seawater filter, 67
Seawater inlet, 66, 68
Seawater outlet, 68
Seawater pipes, 67
Crane transport
Engine with gearbox, 153
Engine without gearbox, 152
Crankshaft axial clearance, Checking, 156
D
Display systems and instruments, System over
view, 127
Index
221
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Index
M Technical data
MAN Monitoring and Diagnostic System (MMDS), Heavy duty, 209
128 Light duty, 201
Modifications and conversions, 15 Medium duty, 205
Throttle lever control system
O
Connecting cable, 111
Oil pressure, Checking the pressure increase, 191
Control, 114
Operating ranges, 94
External throttle lever control system, 113
Operator's responsibility, 141
Internal throttle lever control system, 109
Override button, Connecting, 137
Termination resistors, 111
Override system, Function, 137
Torsional-vibration analysis, 40
P
V
Personal protective equipment, 143
V-Drive, 39, 40
Personnel, Requirements, 142
Vessel potential, 217
Planning, Engine and gearbox installation, 13 - 37
Power take-off, 99 W
Propeller, Load indication, 92 Warning device, acoustic, 126
Propeller shafts What to do in the event of danger, 148
General, 43
Installation, 165
Propeller system, 89
Controllable pitch propeller, 95
Fixed pitch propeller, 89
R
Replacement parts, 11
Resilient engine mounts
Description, 31
height adjustment, 160
Installation, 157
Resilient mounts
Engine and gearbox mounts, 32
Flange-mounted V gearbox, 33
S
Safety equipment, 16, 147
Seawater pump
Delivery quantities, light duty, 204
Delivery quantities, medium duty, 207, 211
Delivery rates, 68
Signs and notices, 16, 149
Specific dangers, 144
Start interlock, 116
Start/stop device, 124
Starting and stopping the engine, 197
Index
223
MAN marine diesel engines D2868 LE4.. / D2862 LE4..
Index
Index
224