Troubleshooting Guide 703-20

MAN Diesel

If you encounter difficulties while operating the ME-engine, this guide can be useful in solving the
problems.

The information in this chapter will help you with:

1. Cylinder Components, Tests and Evaluation

2. Test for Earth Failure in the ECS System.

1. Cylinder Components, Tests and Evaluation

This document describes the usage of troubleshooting diagrams and procedures. The procedures
only focus on cylinder components (excluding cylinder lubricating components).

Cylinder Fault Diagram

The Cylinder Fault Diagram (CFD – pages 2 and 3 this section) describes the correlation between
system failures and symptoms (alarms and other known symptoms).
The crosses in the diagram indicate the symptoms that can be generated from a certain failure/
cause.

Cylinder Loop Test (flowchart)

The Cylinder Loop Test (CLT – pages 4 and 5 this section) is a description of a test procedure. The
CLT can isolate failures on cylinders where it is known that there is an error.

The test categorises failures in: FIVA valve, FIVA sensor, cabling, MPC, exhaust valve system, ex-
haust valve sensor, fuel plunger system, fuel plunger sensor and hydraulics.

This makes reference to the below mentioned tests.

Please note that there are separate tests for different FIVA valve types.

Amplifier Test (flowchart)

The Amplifier Test (AT – page 6 this section) is a description of a test procedure. The AT should be
used to isolate failures in the amplifier loop if it is known that there is an error.

The test categorises failures in: amplifier, power cabling, cabling to amplifier, FIVA and MPC.

The test is only applicable on systems with Curtiss Wright FIVA valves.

Sensor Chain Test (flowchart)

The Sensor Chain Test (SCT - page 7 this section) is a description of a test procedure. The SCT
should be used to isolate failures in sensor chains where there is a supervision alarm or another
error.

The test categorises failures in: sensor, cabling, MPC.

When referring to this page, please quote Operation 703-20 Edition 0005 Page  (9)
 703-20

Page  (9)
Symptoms Possible Failures
FIVA Alarms Hydraulic failure
FIVA position feedback signal failure Fuel Plunger failure (Suction Valve)
FIVA Amplifier current Supervision (0 = Current) Low fuel oil pressure
FIVA Amplifier reports internal faults (Too high current) FIVA failure
Illegal position (FIVA pilot spool, window function) Exhaust Valve failures
Fuel Plunger and Exhaust Valve Alarms Non-return valves
Exhaust Valve open stroke low High-Pressure pipes
X X
Illlegal plunger position (Window function) Lack of pressure oil
X
Supervision Alarms Air Spring ventet hole failure
X
Superv. Ch30, 4102 Proportianl Valve position Electronics failure
X
Superv. Ch31, 4114, Plunger position M CW FIVA Amplifier failure
X
Superv. Ch34, 4111, Exhaust Valve position MPC failure
X
Superv. Ch33, 4106, Valve Amplifier Ac Sensor failures
X X X
Misc. Alarms Exhaust Valve position feedback failure
X X X
Frozen IO detected (Ch 30) Fuel Plunger position feedback failure
X X
Other Symptoms CW FIVA Pilot valve feedback failure
X
No fuel injection Cabling failure
X
Low Pmax
X X
Low MIP
X X X X
Increased fuel index
X X
Plunger sticking in top
X
Exhaust Valve noice
X X X
Exhaust Valve knocking
X X X
Exhaust Valve not moving
X
X X X
X X
Accumulators (One CCU) or Hydraulic X X
Power Supply (Many CCU’s)
X X X
Troubleshooting Guide

X X
If failure occurs on many cylinders - root cause can X To further identify the failure in these single alarm cases:
be extreme ambient conditions or water in oil perform sensor chain test
X X
Cylinder Components Failure Tree (CFD – Curtiss Wright FIVA)

To further seperate between these failures: To isolate failures in amplifier chain

Perform “Cylinder Loop Test”. perform amplifier chain test

To isolate this failure, perform Amplifier chain test

X This failure can generate this alarm

This failure can only generate this alarm
if it also generates other alarms
Additional Information

When referring to this page, please quote Operation 703-20 Edition 0005
MAN Diesel
 3YMPTOMS 0OSSIBLEæ&AILURES
MAN Diesel

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&)6!æPOSITIONæFEEDBACKæSIGNALæFAILURE &UELæ0LUNGERæFAILUREæ3UCTIONæ6ALVE
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8

When referring to this page, please quote Operation 703-20 Edition 0005
Troubleshooting Guide

8 8 PERFORMæSENSORæCHAINæTEST
)FæFAILUREæOCCURSæONæMANYæCYLINDERSæçæROOTæCAUSEæ
Cylinder Components Failure Tree (CFD – MBD Parker FIVA)

CANæBEæEXTREMEæAMBIENTæCONDITIONSæORæWATERæINæOIL

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703-20

Page  (9)
703-20 Troubleshooting Guide
MAN Diesel

Cylinder Loop Test (CW-FIVA)

Preparation

- Put CCU in test-mode Amplifier ch33 No

- Hydraulic pressure and fuel value test 1 & 2
pressure must be present OK ?
- Have an engineer stand by
for feeling and listening to
fuel and exhaust valve pipes
Yes Yes Failure in amplifier,
Other tests or amplifier cabling or
events failed ? MPC (ch70).
Go to amplifier test

- Set ch70 to: 0V No

- Set ch60 to: ON
(Enables FIVA
amplifier)
Failure in cabling or
FIVA Pos., ch30 No MPC (ch33)
value test 1 & 2
OK ?

- Set ch70 to: 3,4V

(This will cause fuel
Yes
injection) Fuel plunger ch31 test Yes
(1 or 2) OR fuel injection failed ?
or exhaust valve (ch34) test (1 or 2) Failure in FIVA or hydraulics
or exhaust valve
opening failed.
Test 1
Read values:
MUST BE DONE IMMEDIATELY
FIVA Pos., ch30:_________(<6mA)
Fuel plunger ch31:______(>8mA) No Failure in FIVA, FIVA
Amplifier, ch33:__________(3,4V) sensor, sensor cable or
Exhaust valve ch34:_____(<8mA) MPC (ch30). Go to
Fuel plunger ch31 No “Sensor Chain Test”
value test 1 & 2
OK ?

Observe events by engineer

standing by: Yes Yes
Fuel injection: evaluate sound Fuel injection AND no Failure in fuel plunger
and shockwave in pipe OK ?____ other failures ?

No

- Set ch70 to: 0V Exhaust valve (ch34) Yes

value-test 1 or 2 failed ?
or exhaust valve
opening failed ?
No Failure in fuel plunger
sensor , sensor cable or
Test 2 MPC (ch31). Go to
“Sensor Chain Test”
Read values:
MUST BE DONE IMMEDIATELY Exhaust valve ch34 No
FIVA Pos., ch30:________(>17mA) value test 1 & 2
Fuel plunger ch31:______(<8mA) OK ?
Amplifier, ch33:__________(0V)
Exhaust valve ch34:____(>10mA) Yes Yes Failure in exhaust valve.
Exhaust valve Check additional
opening failure ? symptoms

Observe events by engineer

standing by: No
Exhaust valve: evaluate sound
and shockwave in pipe OK ?____
Failure in exhaust valve
Non-static failure or test sensor , sensor cable or
unable to detect failure MPC (ch34). Go to
“Sensor Chain Test”

Page  (9) When referring to this page, please quote Operation 703-20 Edition 0005
 Troubleshooting Guide 703-20
MAN Diesel

Cylinder Loop Test (MD-FIVA)

Preparation

- Put CCU in test-mode

- Hydraulic pressure and fuel
pressure must be present
- Have an engineer stand by
for feeling and listening to
fuel and exhaust valve pipes

- Set ch70 to: 10 mA FIVA Pos., ch30

value test 1 & 2
OK ?

Yes
Fuel plunger ch31 test Yes
- Set ch70 to: 14 mA (1 or 2) OR fuel injection failed ?
(This will cause fuel or exhaust valve (ch34) test (1 or 2) Failure in FIVA or hydraulics
injection) or exhaust valve
opening failed.

Test 1
Read values: No Failure in FIVA, FIVA
MUST BE DONE IMMEDIATELY sensor, sensor cable or
FIVA Pos., ch30:_________(<6mA) MPC (ch30). Go to
Fuel plunger ch31:______(>8mA) Fuel plunger ch31 No “Sensor Chain Test”
Exhaust valve ch34:_____(<8mA) value test 1 & 2
OK ?

Yes Yes
Fuel injection AND no Failure in fuel plunger
Observe events by engineer other failures ?
standing by:
Fuel injection: evaluate sound
and shockwave in pipe OK ?____ No

Exhaust valve (ch34) Yes

value-test 1 or 2 failed ?
or exhaust valve
- Set ch70 to: 10 mA opening failed ?
No Failure in fuel plunger
sensor , sensor cable or
MPC (ch31). Go to
“Sensor Chain Test”
Exhaust valve ch34 No
Test 2 value test 1 & 2
Read values: OK ?
MUST BE DONE IMMEDIATELY
FIVA Pos., ch30:________(>17mA)
Fuel plunger ch31:______(<8mA)
Yes Yes Failure in exhaust valve.
Exhaust valve Check additional
Exhaust valve ch34:____(>10mA)
opening failure ? symptoms

No
Observe events by engineer
standing by: Failure in exhaust valve
Exhaust valve: evaluate sound Non-static failure or test sensor , sensor cable or
and shockwave in pipe OK ?____ unable to detect failure MPC (ch34). Go to
“Sensor Chain Test”

When referring to this page, please quote Operation 703-20 Edition 0005 Page  (9)
703-20 Troubleshooting Guide
MAN Diesel

Amplifier Test (CW-FIVA)

- CCU in test mode
- set ch 70 to 0V
- Set ch 60 to ON
(amplifier)

Set ch 70 to 0.6 V

Yes Try different values Amplifier Yes Test cannot find

Amplifier on ch 70 (max 3.4 V). Ch 33 = input fault in amplifier
Ch 33 = 0.6 V ? Fuel injection risk on ch 70 ? chain
above 1.6 V

No No

Check cabling

Replace Amplifier
with spare

Yes
Ch 33 = input Failure in amplifier Distribute
on ch 70 ? components: Further diagnosis
- Original amplifier on
cylinder +1,
No - Original MPC on
cylinder +2,
- Original FIVA on
Reattach original
cylinder +3,
amplifier
- Run as normal until
problem re-occur.

Replace MPC
with spare

Yes
Problem on original Failure in cabling
Yes cylinder ? or plugs
Ch 33 = input Failure in MPC
on ch 70 ?

No
No
Reattach original Problem on
Yes
MPC cylinder +1 ? (original Failure in amplifer
amplifier)

Replace FIVA
with new No

Problem on Yes
cylinder +2 ? (original Failure in MPC
Yes MPC)
Ch 33 = input Failure in FIVA
on ch 70 ?

No
No
Reattach orignal Problem on Yes
FIVA cylinder +3 ? (original Failure in FIVA
FIVA)

Failure in cabling
or plugs

Page  (9) When referring to this page, please quote Operation 703-20 Edition 0005
 Troubleshooting Guide 703-20
MAN Diesel

Check cables
Sensor Chain Test
thoroughly

Connect a spare
sensor temporarily
(do not mount
spare sensor)

Yes On MPC, exchange

Reconnect original plugs with another
Alarm still present ?
sensor channel with cable
supervision,
eg. ch30, 31, 34
No

Attach original sensor Yes

on another channel Did alarm change
with cable channel ?
supervision,
eg. ch30, 31,34
No

No No
Alarm present on Alarm still present
new channel ? on original channel ?

Yes Yes

Failure in sensor Non-constant MPC input Failure in cable

failure channel failure

Further diagnosis

Yes
Alarm on original
Failure in cable
cylinder ?

Move sensor to No
cylinder +1 and MPC
to cylinder +2
Yes
Alarm on cylinder +1 ? Failure in sensor
(original sensor)

Continue normal
operation untill same No
alarm appears again

Yes
Alarm on cylinder +2 ? MPC input
(oiginal MPC) channel failure

No

Unrelated error

When referring to this page, please quote Operation 703-20 Edition 0005 Page  (9)
703-20 Troubleshooting Guide
MAN Diesel

2. Test for Earth Failure in the ECS System

Method 1.

Fault isolation of an earth ground failure

A certain and fast method (compared to method 2 below).

Precondition: The engine must be stopped and in FWE.

1. Disconnect the isolation monitor unit (e.g. Bender xxx) from the power supply.

2. Measure the current between ground (a non-isolated point of the engine or ship steal structure)
and 0 Volt, and ground and 24 Volt, respectively, by means of an ampere meter (a multimeter in
current mode) in serial with a 2 kOhm resistor. The measurement can practically be done either
in the power supply of the ECS or in the power distribution box on the engine. If any of the cur-
rents are higher than 0.2 mA, the isolation to ground is too low. In a properly isolated system,
the current will be lower than 0.2 mA.

3. Disconnect the power plugs (J1) (which disconnects both 0 Volt and 24 Volt) for one MPC at a
time until the MPC containing the isolation fault is found, i.e. when the current drops below 0.2
mA.

4. The power plug to the MPC causing the isolation failure is connected again, and the connectors
for sensors and external signals are disconnected one at a time, until either a sensor is found
that causes the isolation failure, or all connectors have been disconnected. Ground current must
be checked as described in Item 2 between 0 Volt and 24 Volt, respectively, while each connec-
tor is disconnected.

5. If the isolation failure is located to a sensor, its cabling must be checked and perhaps the sensor
must be exchanged.

6. If the isolation failure is still present after all connectors to external signals are disconnected,
while the power connector is still connected to the MPC, the failure is probably in the MPC,
which must then be exchanged.

When the problem has been rectified, all connectors and plugs are reinstalled, and the isolation
monitor is reconnected. Check that the isolation monitor no longer initiates an alarm (note that fail-
ures might be present in more than one unit (MPC) at a time).

Method 2

A certain but slow method.

Precondition: The engine must be stopped and in FWE.

1. Disconnect the power plug (J1) (which disconnects both 0 Volt and 24 Volt) in one of the MPCs .

Page  (9) When referring to this page, please quote Operation 703-20 Edition 0005
 Troubleshooting Guide 703-20
MAN Diesel

2. Wait one minute - check the isolation value on the isolation monitor (e.g. Bender xxxx) in power
supply A.
If the isolation value is still lower than 24 kOhm (the alarm level), then repeat point 1 in the next
MPC. In a properly isolated system the isolation is higher than 100 kOhm.

3. Repeat point 1 and 2 for each MPC until the MPC containing the isolation fault is found, i.e.
when the isolation comes above 100 kOhm.

4. The power plug to the MPC causing the isolation failure is connected again.

5. One of the connectors (J2 - J85) for the sensors and external signals is disconnected.

6. Wait one minute - check the isolation value on the isolation monitor as in point 2.

7. Repeat point 5 and 6 for each of the connectors for external signals until either a sensor is found
that causes the isolation failure (the isolation comes above 100 kOhm), or all connectors have
been disconnected.

8. As method 1 point 5 or point 6.

When the problem has been rectified, all connectors and plugs are reinstalled. Check that the isolation
monitor no longer initiates and alarm (note that failures might be present in more than one unit (MPC) at
a time).

Method 3

A faster, but uncertain method.

Precondition: The engine must be stopped and in FWE.

1. Disconnect the isolation monitor unit (e.g. Bender xxxx) from the power supply.

2. Connect a voltmeter between the 0 Volt and ground (a non-isolated point of the engine or ship
steel structure) and, if possible, another voltmeter between 24 Volt and ground. Alternatively one
voltmeter must be connected alternately between 0 Volt and 24 Volt.
The measurement can practically be done either in the power supply of the ECS or in the power
distribution box on the engine.
When using this method both measured values should be within 10 - 16 V (+ or -) if the system
has normal isolation to ground, while an isolation failure normally causes one of the measure-
ment to be below 5 V and the other above 20 V.

3. The further procedure is similar to method 1 above, except that pin pointing of the isolation fault
is based on the voltage measurements being in the isolation fault or normal range as specified
in previous point 2.

When the problem has been rectified, all connectors and plugs are reinstalled, and the isolation monitor
is reconnected. Check that the isolation monitor no longer initiates an alarm (note that failures might be
present in more than one unit (MPC) at a time).

When referring to this page, please quote Operation 703-20 Edition 0005 Page  (9)