Man D 0836 LE 401 - User Manual

This document provides operating instructions for MAN Marine Diesel Engines, specifically models D 0836 LE 401 and D 0836 LE 402. It covers commissioning, operation, maintenance, and troubleshooting, emphasizing safety and environmental protection.

Function Description

The MAN Marine Diesel Engines D 0836 LE 401 and D 0836 LE 402 are in-line vertical, 4-stroke diesel engines with turbocharging, intercooling, and wastegate. They utilize direct injection and an Electronic Diesel Control (EDC) system (Model MS6.4) for precise fuel management. The engines are designed for marine propulsion, with control systems like Marex SB or Mini Marex from Bosch-Rexroth managing engine speed and gearshift. The control systems allow for various operational modes, including warming up, increased idling speed, and synchronization in twin-engine setups. Monitoring and alarm systems (MMDS D08-L and MMDS-LC) provide comprehensive oversight of engine parameters and alert operators to potential issues through optical and acoustic signals.

Important Technical Specifications

• Model: D 0836 LE 401 / 402
• Design: In-line vertical
• Cycle: 4-stroke Diesel with turbocharging / intercooling and wastegate
• Combustion system: Direct injection
• Turbocharging: Turbocharger with intercooling and wastegate
• Number of cylinders: 6
• Bore: 108 mm
• Stroke: 125 mm
• Swept volume: 6,870 cm³
• Compression ratio: 15:1
• Rating:
  • D 0836 LE 401: 331 kW / 450 hp at 2600 rpm
  • D 0836 LE 402: 265 kW / 360 hp at 2400 rpm
• Firing order: 1-5-3-6-2-4
• Valve clearance (cold engine):
  • Intake: 0.50 mm
  • Exhaust: 0.60 mm
• Valve timing:
  • Intake opens: 18° before TDC
  • Intake closes: 32° after BDC
  • Exhaust opens: 63° before BDC
  • Exhaust closes: 29° after TDC
• Injection pump: Bosch-distributor-type injection pump VP44
• Governor: Electronic Diesel Control (EDC) – Model MS6.4
• Start of delivery (D 0836 LE 401): 0° ± 0.5° before TDC
• Injectors: Six-hole nozzles
• Opening pressure of injector:
  • New nozzle holder: 300 + 8 bar
  • Used nozzle holder: 300 + 8 bar
• Engine lubrication: Force feed
• Oil capacity in oil sump (litres): min. 24 l, max. 28 l
• Oil change quantity (with filter): 30 l
• Oil filter: Full-flow filter with two paper filter elements
• Engine cooling system: Liquid cooling
• Coolant temperature: 80 - 90°C, temporarily 95°C allowed
• Coolant filling quantity: 58 l
• Electrical equipment:
  • Starter: 24 V; 4 kW
  • Alternator: 28 V; 55 A

Usage Features

The engines are designed for straightforward commissioning and operation. Before first commissioning, new or overhauled engines require a run-in period, gradually increasing load over the first few hours of operation. Fuel, lubricants, and coolants must adhere to MAN's regulations to ensure warranty validity and optimal performance. The control systems offer intuitive operation for engine speed and gearshift (forward, neutral, reverse).

The MMDS D08-L and MMDS-LC display units provide comprehensive monitoring of engine parameters such as oil pressure, coolant temperature, charge air temperature, boost pressure, and battery voltage. These units also feature an alarm system that indicates engine faults optically and acoustically, with different LED behaviors for pre-alarms, master alarms, slowdown alarms, and shutdown alarms. Operators can acknowledge alarms, perform lamp tests, and reset alarms after the fault has been rectified. The display units allow for customization of display units (metric or English) and illumination intensity.

The Marex SB and Mini Marex control systems facilitate bridge changes, warming up the engine without engaging the gearbox, and increasing idling speed for auxiliary power needs. In twin-engine configurations, a synchronization function automatically sets the same setpoint for both engines if their accelerator positions are within a 10% divergence. The Mini Marex system also includes a "trolling function" for low-speed operation, allowing for variable clutch slip and engine speed adjustment.

Safety is paramount, with instructions for emergency stop buttons, proper handling of service products, and precautions during operation and maintenance.

Maintenance Features

The manual details essential maintenance procedures to ensure the longevity and reliable operation of the engines. Key maintenance tasks include:

• Oil System: Checking oil level (between min and max marks on the dipstick), refilling with approved engine oil, and changing the oil filter. Used oil and filters are classified as dangerous waste and must be disposed of properly.
• Fuel System: Draining moisture from parallel fuel filters, changing fuel filters (only when the engine is switched off), bleeding the fuel system after filter changes or if air enters the high-pressure part of the injection pump. The fuel pre-cleaner can be cleaned by removing the filter housing, washing it in clean diesel fuel, and blowing it out with compressed air.
• Cooling System: Draining the cooling system (when cold) by removing drain plugs from the oil cooler housing and turbine housing, and filling with a mixture of drinkable tap water and anti-freeze/anti-corrosion agent. Coolant must be added at the filler neck only, and the system should be bled.
• V-belts: Checking V-belts for cracks, oil, overheating, and wear, and checking/adjusting tension using a V-belt tension tester.
• Alternator: The alternator is maintenance-free but requires protection from dust and moisture. Specific instructions are provided to prevent damage to the alternator during engine operation.

The manual also outlines procedures for temporary decommissioning of engines, requiring anti-corrosion protection according to MAN works norm M 3069 for long periods out of service. It emphasizes the importance of entrusting MAN Local Service Centres with disturbance removal and repair work.