Installation Instructions D2676LE4xx
Installation Instructions D2676LE4xx
Installation Instructions D2676LE4xx
Subject to amendment.
The information, text, drawings, pictures and other illustrations that it contains are protected by copyright
and are subject to industrial property rights. Any misuse is punishable by law.
It is not permitted to change the contents of this document. The same applies to changes to the context of
individual chapters and/or the whole document. MAN Truck & Bus AG assumes no liability for any
damages arising from non-compliance with the above provisions.
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of
MAN Truck & Bus AG. All rights deriving from copyright law are expressly reserved by MAN.
2017
MAN Truck & Bus AG
Vogelweiherstrasse 33
90441 Nuremberg
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1932
E-Mail: Engine-Documentation@man.eu
Internet: www.man-engines.com
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Information about this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Instructions for using this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Additional documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Applicability and validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Installing a new engine in a vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Installation acceptance testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Liability for material defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.10 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.11 Technical documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.12 Explanation of icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Engine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Requirements for the engine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Engine weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Maximum engine inclination angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6 Resilient mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 Selecting a suitable resilient mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Resilient mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.1 Basic design concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.2 Structure of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.3 Permitted exhaust back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12.1 Seawater cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12.2 Seawater intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
12.3 Components of seawater supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.4 Seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
12.5 Gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
12.6 Material selection for piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
14 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
14.1 Schematic diagram of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
14.2 Fuel pre-filter with water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
14.3 Additional fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
14.4 Fuel overflow connection * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
14.5 Fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
15 Propeller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
15.1 Fixed pitch propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
15.2 Load indicator on the display instrument of the MAN Monitoring and Diagnostic System
(MMDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
15.3 Operating ranges for marine engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
40 Folders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
40.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
40.2 Technical terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
40.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1 Foreword
Emission-related installation instructions
“Failing to follow these instructions when installing a certified engine in a vessel violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act”.
Some engines are only certified as recrational engines or for fixed pitch propeller applications. Please refer
to the Emission Control Information Label on your engine to check the certification status. To install the
engine in an application for which it is not certified, is a violation against the Federal Clean Air Act.
S Emission label
If you install the engine in a way that makes the engine´s emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment as described in
(40 CFR 1068.105).
See page 25.
The above information concerning only the scope of the US Environmental Protection Agency (EPA).
NOTE
When putting an engine in service, important parameters are recorded and evaluated which are
essential for the engine's operational safety.
Therefore:
S Engines should only be put in service by MAN authorised personnel.
NOTICE
This installation manual is a resource for the equipment manufacturer. However, it does not
replace the personal consultation with the MAN-installation consulting service.
For this reason:
S Questions arising on reading this installation manual that are related to correct installation of the MAN
engines and components must be clarified with MAN.
The operating instructions and maintenance instructions as well as the consumables recommendations, are
included in the scope of supply of the engine or to be obtained from MAN.
The nearest MAN service center must be called in if malfunctions occur and for all checks, adjustments
and repairs, particularly during the warranty period.
WARNING
Risk of injury from incorrect spare parts
Incorrect or faulty spare parts can lead to damage, malfunction or total failure and impair safety.
Therefore:
S Recommendation: Only use genuine MAN spare parts
Warnings
Warnings in this manual are identified by icons. The information has been introduced with signal
words that express the extent of risk or danger.
Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and
material damage.
DANGER
Describes an immediate dangerous situation that will lead to severe injuries or death if it is not avoided.
WARNING
Describes a potentially dangerous situation that may lead to severe injuries or death if it is not avoided.
CAUTION
Describes a potentially dangerous situation that may lead to minor or moderate injuries if it is not
avoided.
NOTE
Describes a potentially dangerous situation that may lead to damage to property if it is not avoided.
ENVIRONMENTAL NOTE
Tips on conduct for environmental protection.
General information
• This symbol displays a list at the first level.
► This symbol displays an action or series of actions.
[1] This symbol displays the position of a special tool according to the list in the section
(1) This symbol displays the position of a graphic in the text.
1 This symbol indicates an item of a graphic display in the text.
Installation planning
DANGER
Danger resulting from improper use
Any use going beyond that intended and / or any other use if the engine may lead to dangerous
situations and this terminates the operational permit.
Therefore:
S Use the engine only as intended.
WARNING
Risk of injury from easily inflammable substances
Easily inflammable substances, liquids or gases cause a fire.
For this reason:
S Smoking, open flames or ignition sources are prohibited in the hazard zone and its vicinity.
S Keep fire extinguishers handy.
S Report suspicious substances, liquids or gases immediately to the person in charge.
S Repair any leaks.
S Discontinue work immediately in case of fire. Leave the hazard zone until the warning is withdrawn.
S Equip the engine compartment with fire alarm device and automatic fire-extinguishing system.
WARNING
Risk of crushing due to moving components
Rotating and linearly moving components cause injuries.
For this reason:
S Follow the accident prevention regulations.
S Rotating machine parts to be provided with a suitable touch protection.
S Never remove protective equipments in front of the rotating components.
2.6 Welding
NOTE
Risk of material damage due to welding
Damage to components
For this reason:
S Welding of any kind must be clarified with the system supplier and must be carried out following
specific instructions.
S MAN assumes no liability for damages caused by welding being carried out improperly.
WARNING
Risk of personal injury due to use of pressurized air and/or water for cleaning
Eye and/or skin injury and/or scalding.
For this reason:
S Always wear protective clothing, protective face shield, safety gloves, and safety shoes.
S Reduce the maximum air pressure to 205 kPa (30 psi).
S Reduce the maximum water pressure to 275 kPa (40 psi).
Pressurized air and water can cause debris and/or hot water to be blown out. This could result in personal
injury. Always wear a protective face shield, protective clothing, and protective shoes when cleaning
components. The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when
the air nozzle is deadheaded and used with effective chip guarding (if applicable) and personal protective
equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
2.9 Labeling
The following symbols must be placed near the hazard zone.
WARNING
Risk of injury due to illegible symbols
Stickers and symbols can become dirty or become otherwise unrecognisable in the course of time.
Therefore:
S Always keep all safety, warning and operating instructions in a clearly legible condition.
S Clean or replace illegible safety, warning and operating instructions
No trespassing
Areas designated in this manner may not be entered.
Electrical voltage
Only qualified electricians are allowed to work in working areas marked in this manner.
Unauthorised persons should not enter areas marked in this manner.
Hot surfaces
Hot surfaces, such as hot engines and hot fluids, are not always perceptible.
Do not touch them without protective gloves.
Risk of injury
If the instructions are not observed, there is a risk of injury.
WARNING
Risk of crushing due to moving components
Rotating and linearly moving components cause injuries.
For this reason:
S Follow the accident prevention regulations.
S Rotating machine parts to be provided with a suitable touch protection.
S Never remove protective equipments in front of the rotating components.
NOTE
Engine damage due to faulty design of components in the engine environment.
Therefore:
S Adapt all components in the engine environment to the engine with respect to design and scale.
NOTE
S Destroy any unused duplicate labels → as required in EPA CFR title 40 part 1068.105 (c)
The engines
Page 26 shows engine views of a D2676 LE4.. engine, each without transmission.
Depending on the scope of delivery, the engine can also be equipped with a flat oil pan (see installation
drawing) and/or hull-mounted cooling system (page 75)
The D2676 LE4.. engine, available in different power ratings depending on the respective application.
DANGER
In case of emergency, the engine must be able to be stopped quickly and reliably, including
from within the engine room.
Therefore:
S The red emergency stop button on the terminal box must be quickly and safely accessible.
The E-box (1) must be mounted in the engine room in an easily accessible location. An emergency stop
button (2) is located on E-box (2).
Recommendation:
Install the E-box (1) with the emergency stop button (1) in the near of the access (door/hatch) in the engine
room.
A description of the E-box is found on page 115.
NOTE
High degree of engine reliability ensured by regular inspection and maintenance work
Low maintenance costs by saving time
Therefore:
S During engine installation, ensure that there is sufficient room for regular maintenance work in
accordance with the maintenance plan.
NOTE
Simple visual inspections can help detect the causes of malfunctions early on.
Therefore:
S There must be a sufficient amount of room for inspecting the engine for oil, coolant or seawater leaks.
S Hose connections and pipes to and from the engine must be easily accessible.
(e.g. V-Engine)
Anwendertipp
For the version with engine cover, the middle
cover can be unclip.
S Filling up coolant
(description found in “Start-up section”)
Height of the deck over the filler cap (1):
H=500 mm (recommendation).
S Checking the coolant level (2)
(description found in “Start-up” section).
5 Engine foundation
kW (hp) rpm kg
Light-duty operation
D2676 LE423 588 (800) 2300 approx. 1210 - 1340
D2676 LE443 537 (730) 2300 approx. 1210 - 1340
Medium-duty operation
D2676 LE422/LE425 478 (650) 2100 approx. 1210 - 1340
D2676 LE432/LE435 412 (560) 2100 approx. 1210 - 1340
Heavy-duty operation
D2676 LE421/LE424 382 (520) 1800 approx. 1210 - 1340
D2676 LE431/LE434 324 (440) 1800 approx. 1210 - 1340
D2676 LE441 270 (367) 1800 approx. 1210 - 1340
D2676 LE451 210 (286) 1800 approx. 1210 - 1340
D2676 LE461 147 (200) 1800 approx. 1210 - 1340
Fore-and-aft Athwartship
max. installation inclination angle 10_ 10_ 0_
NOTE
The angle of 10° degrees at the free end may only occur when in operation.
Therefore:
S The installation inclination angle to the free end side is 0_.
Fore-and-aft Athwartship
max. installation inclination angle 10_ 10_ 0_
NOTE
The angle of 10° degrees at the free end may only occur when in operation.
Therefore:
S The installation inclination angle to the free end side is 0_.
6 Resilient mounts
NOTE
The resilient engine mounts cannot eliminate vibrations due to poor alignment of the drive system
or oscillations induced by the propeller.
Therefore:
S Align the drive system carefully, see page 171.
(1) Engine
(2) Resilient engine mount, see page 42
(3) Flywheel housing, see pages 45, 166
(4) Resilient gearbox mount, see page 42
(5) Marine reverse gear unit, flanged onto the flywheel housing
(6) Gearbox oil cooler, see page 73
DANGER
Risk of fatal injury due to rotating machine parts
Therefore:
S Rotating machine parts (shafts, flanges) must be provided with suitable guards for safety reasons.
Adhere to safety regulations!
NOTE
Perform an exact installation investigation in accordance with the project.
Therefore:
S Request an installation drawing with detailed dimensions of the flywheel and flywheel housing.
8.3 Flywheels
NOTE
Perform an exact installation investigation in accordance with the project.
Therefore:
S Request an installation drawing with detailed dimensions of the flywheel and flywheel housing.
8.4 Clutches
DANGER
Risk of fatal injury due to rotating machine parts
Therefore:
S Rotating machine parts (shafts, flanges) must be provided with suitable guards for safety reasons.
Adhere to safety regulations!
8.5 Propshafts
ß1
ß2
Exception:
If the propshaft has a three-dimensional deflection
angle, the input and output shafts are not on
the same plane. To obtain a uniform output
movement, the inner joint forks must be twisted
relative to each other such that each fork ends up
in the plane of deflection of its joint. The spatial
deflection angles must also be the same size.
NOTE
Damage to electronics components in the electrics case
Therefore:
S Temperature inside the electrics case: max. 70 _C.
Loss of engine power should be expected if the temperature of the intake air is over 45 _C.
The following is an indication for sufficient engine room ventilation:
Engine room temperature = ambient temperature + 15 _C (max. 20 _C)
Measured at the front of the engine room, the rear of the engine room and the air filters.
The temperature in the engine room depends essentially on the following boundary conditions:
The air requirement indicated in the table is the combustion air requirement for each engine.
The air inlets in the engine room should be scaled at least for this flow rate. (X-number engines)
9.3.1 Fans
NOTE
Water ingress results in total loss of the engine
Therefore:
S Spray and splash water are not allowed near the engines.
NOTE
Exceeding the maximum permissible intake vacuum leads to poor performance, overheating,
black smoke and ultimately to engine damage.
Therefore:
S During commissioning, the intake vacuum must be measured.
NOTE
Exceeding the maximum permissible combustion air temperature downstream of the intercooler
leads to engine damage as a result of thermal overload
Therefore:
S An alarm is triggered by the engine monitoring system if the maximum permissible combustion air
temperature is exceeded and if neccessary the power is reduced to protect the engine.
11 Exhaust system
DANGER
Exhaust gases are toxic and hot.
Therefore:
S The exhaust system must be completely gas-tight.
S Use fire retardant insulation material for the exhaust system.
(Surface temperature < 220 °C)
NOTE
Engine damage due to the intrusion of seawater into the exhaust system
Therefore:
S Install pipe elbows into the exhaust pipe.
NOTE
Improper exhaust system support may result in damage to turbocharger
Therefore:
S Exhaust pipes must be attached and supported such that no forces affect the turbo charger in
operating conditions (650 °C).
NOTE
Turbocharger damage due to exceeding the maximum permissible turbo charger speed
Therefore:
S Intake vacuum at the exhaust outlet is unacceptable.
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
stationary or moving at low speed until this pressure exceeds the water pressure below the ship and then
escapes abruptly, resulting in intense vibrations
DANGER
Risk of fire due to hot surfaces in contact with diesel fuel and oil.
Risk of burns on hot surfaces
Therefore:
S Use fire retardant insulation material for the exhaust system.
NOTE
Component damage due to exceeding the maximum allowable temperature of the electronic
components in the electrics case.
Therefore:
S Do not let the engine room temperature exceed 60 _C.
NOTE
Engine damage due to thermal overload
Excessive exhaust back pressures lead to high exhaust temperatures, insufficient engine power,
increased amounts of smoke and consequently to engine damage due to thermal overload.
Therefore:
S During the start-up process, the exhaust back pressure must be measured.
S The permissible exhaust back pressure at full load and nominal (engine) speed is: 20-80 mbar.
NOTE
Turbocharger damage due to exceeding the maximum turbo charger speed
Therefore:
S Partial vacuum at the exhaust outlet not allowed.
12 Cooling system
Seacocks
Seawater strainer
Seawater pump:
Supply quantity of the seawater pump (1).
450 l/min at 2300 rpm.
400 l/min at 2100 rpm
350 l/min at 1800 rpm
Seawater intake
The connection line from the seawater filter is
connected to the seawater intake (1).
Seawater outlet
The vessel-side piping is connected at the
seawater outlet (1). The seawater is often injected
into the exhaust system, see page 64.
The minimum cross-section of the vessel-side
piping must correspond to the connection
cross-section on the engine.
Alternative:
Take the seawater at the connection (2) and conduct after the gearbox oil cooler outwards.
► Limit the max. flow with orifices.
For the engine cooling must flow through the heat exchanger at least xxx liters / min!
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.
Engine
(9) Intercooler
(10) Engine crankcase
(option 1)
(option 2)
NOTE
Engine damage due to cooling system malfunction
Therefore:
S Observe the following information regarding the cooling system components.
D2676 LE4..
Air volume in expansion tank with maximum filling litre 6
Coolant volume in expansion tank with maximum filling litre 18 (or more)
Coolant volume range between maximum and minimun litre 6
Technical data
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 kg
Coolant volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to 16 liters
Air percentage basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 liters
Air volume X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 liter
Air volume Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 liter
Valve cover opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief valve 1.4 +0.2 bar
Vacuum valve 0.02-0.1 bar
Air volumes X and Y can be linked with the main volume if necessary.
(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 (M18x1,5)
(M14x1,5) 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
Baffles (1)
S steady the flow,
S improve air separation,
S improve the tank strength.
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
ethylene 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
industrial and marine diesel engines"). A current list of approved products is available online at:
www.asp.mantruckandbus.com
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 b, c and d are interlinked. If the pressure loss in the cooling system (= pressure differential
between feed and return) is increased due to the design, the coolant circulation is reduced, leading to an
increase in the temperature differential between feed and return.
Engine models Engine power Rated speed Heat quantity to Coolant circula Max. pressure
be dissipated tion in high- differential bet
(cooling load) in temperature cir ween feed and
high-temperat cuit return Dp
ure circuit
kW rpm kW litres/min mbar
Light-duty
D2676 LE423 588 2300 300 300 2800
D2676 LE443 537 2300 285 300 2800
Medium-duty
D2676 LE422/425 478 2100 245/255 250 2400
D2676 LE432/435 412 2100 210/220 250 2400
Heavy-duty
D2676 LE421/424 382 1800 180/190 200 2000
D2676 LE431/434 324 1800 156/166 200 2000
D2676 LE441 270 1800 150 200 2000
D2676 LE451 210 1800 125 200 2000
D2676 LE461 147 1800 90 200 2000
The details for the coolant circulation rate and the pressure difference between forward and return define a
typical operating characteristic curve for cooling systems.
Engine models Engine power Rated speed Heat quantity to Coolant circula Max. pressure
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
Light-duty
D2676 LE423 588 2300 120 450 800
D2676 LE443 537 2300 110 450 800
Medium-duty
D2676 LE422/425 478 2100 95/100 400 800
D2676 LE432/435 412 2100 85/90 400 800
Heavy-duty
D2676 LE421/424 382 1800 75/80 350 800
D2676 LE431/434 324 1800 60/65 350 800
D2676 LE441 270 1800 50 350 800
D2676 LE451 210 1800 45 350 800
D2676 LE461 147 1800 30 350 800
The details for the coolant circulation rate and the pressure difference between forward and return define a
typical operating characteristic curve for cooling systems.
14 Fuel system
WARNING
Risk of injury from easily inflammable substances
Highly flammable substances, liquids or gases cause a fire.
For this reason:
S Smoking, open flames or ignition sources are prohibited in the hazard zone and its vicinity.
S Keep fire extinguishers ready for use.
S Report suspicious substances, liquids or gases immediately to the person in charge.
S Repair any leaks.
S Discontinue work immediately in case of fire. Leave the danger zone until given the all clear.
NOTE
JP8 diesel fuel and biodiesel may damage the engine
(1) Fuel feed from the fuel tank to the engine (via the fuel pre-filter)
(2) Fuel pre-filter with water trap
(3) Manual priming pump (included in MAN's scope of delivery)
(4) Fuel feed (Hoseline included in MAN's scope of delivery)
(5) Fuel return (Hoseline included in MAN's scope of delivery)
(6) Fuel return from the engine to the fuel tank (below fuel level)
(7) Fuel tank
H Maximum height 1.5 m
The fuel is delivered from the tank to the engine fuel system via the fuel pre-filter with water trap (2).
Excessive fuel flows back to the tank.
The installation of the fuel pre-filter with water trap (2) is important for engine functioning,
see page 95,as well as the dimensions and spatial configuration of the vessel fuel system's piping to
ensure permissible pressures in the fuel system, see page 97.
NOTE
Long fuel lines and too many bends result a loss of pressure in the fuel system.
The partial vacuum of max. 0.35 bar may not be exceeded even with clogged filters.
Therefore:
S Attach the fuel pre-filter near the engine.
S Install adequately sized piping.
NOTE
Risk of engine damage due to water and dirt in the fuel
Engine damage or reduced engine power due to contaminated fuel.
Therefore:
S Install a fuel pre-filter with water separator (included in MAN's scope of delivery).
A fuel pre-filter with water separator, a manual priming pump, hoses and fittings are delivered along with
the engines.
They should be installed into the fuel supply from the tank to the engine.
The fuel pre-filter supplied by MAN may under no circumstances be substituted with another product.
(example)
UMWELTHINWEIS
Do not allow any diesel fuel to contaminate the
soil or bodies of water.
The operator must ensure that the fuel at the
overflow (1) can flow controlled off (e.g. via
suitable hoseline), in the case of a fuel leakage on
the high-pressure lines.
NOTE
Nonobservance the permissible fuel pressures leads to problems in the high pressure circuit.
Suction -and return pressure are not directly monitored. However, alarms can be trigged with
relating to the high pressure circuit.
15 Propeller system
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
Power in %
50
40
30
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
* Systems with jet drives should also be designed in accordance with this table.
Power in %
(3) Performance reduction curve
(4) Operating point with excessively large propeller 50
3
40
30
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
100
The propeller's power consumption is too low
The propeller cannot consume and transmit the 90
available engine power. The engine speed is then
much higher than the nominal (engine) speed 80
(operating point 4).
70
(1) Engine power curve (qualitative)
1 3
(2) Running resistance curve 60
Power in %
30
2
20
10
0
40 50 60 70 80 90 100 110 120
Speed in %
3
Relative load
Speed in %
The relative value is found by comparing with the maximum possible injection volume, corresponding to
100% (stored in the data record of the control unit).
Speed in %
Operating range
(2) Acceleration
S Brief operation in order to increase the load by increasing engine speed
S Speed lower than 100% of the nominal (engine) speed
S Sustained operation for the operating mode “heavy-duty” is allowed
S Sustained operation for the operating modes “medium-duty” and “light” is not allowed
(3) Normal operation
S Sustained operation allowed, maximum speed 100-102% of the nominal (engine) speed
(4) New condition
S Operating range for new, fully laden vessel
S Sustained operation allowed a maximum speed 102-104% of the nominal speed
(5) Low loads
S Operating range at relatively high speeds and low loads
S Sustained operation is inefficient, however
16 Cabin heating
Anwendertipp
For engines with two alternators, the connecting parts are supplied loose.
NOTE
Risk of engine damage due to low coolant temperatures
Deshalb:
S Permanent motor operation with low coolant temperatures is not allowed.
Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
and the safety notes in all the chapters. 109
Power take-off and hydraulic pumps
18 Electrical system
18.1.1 Starter
18.2 Alternator
NOTE
False alarms due to no ground or improper ground of the E-box
Therefore:
S Connect the ground fitting of the E-box with the vessel and the engine block.
A diagram of wiring of the Electronic terminal box (E-box) with vessel can be found in the appendix of this
manual from page 209 under “Wiring of the basic components”.
(open E-Box)
NOTE
Faulty wiring of the throttle control system and throttle levers leads to malfunctions of data
communication
Therefore:
S Connect CAN-Bus in the correct manner.
PIN Socket
L 40
Terminating resistors
Aventics throttle levers communicate via a CAN bus with the throttle control system in the E-box in the
engine room. This CAN bus must always be equipped at the beginning and the end with a terminating
resistor.
Termination at the beginning of the bus in the engine terminal box
The control system in the engine room has an internal terminating resistor (DIP switch S1)
on the motherboard that does not need to be changed. Default setting: S1 to the right.
S1: Switch for terminating resistor, throttle lever
S2: Switch for terminating resistor, cross communication
NOTE
Malfunctions due to redundancy
CAN termination of cross communication is implemented on both sides by setting the DIP switch S2 to
“ON”. DIP switch S2 of the midengine control system should only be set to “OFF” in case of systems of
more than 2 engines.
Therefore:
S No terminating resistor may be attached to the open connector X13 (e.g. starboard) or X14 (e.g. port).
Close open connectors using caps.
20.2.1 General
As an alternative to internal throttle control, it is possible to control the engine using the external 4-20 mA
current signal of an electric throttle control system (4mA = idling, 20mA = full load).
If the 4-20 mA signal fails, the SFFR deems the system faulty, and the engine continues at idling speed.
When activating via 24V voltage outputs, power must be supplied to the external throttle control system
via X4/pin12 and pin13 in order to obtain the same earth potential.
The external throttle control system must be “earthed” to the ship's potential.
Power supply to the throttle control system via ignition (term. 15 / 31)
Connecting the throttle control system power supply via the shipyard connector X4 (see figure on
page 132) to pin 12 (15+) and pin 13 (31-) (max. 8 A) is recommended.
This ensures that switching off the ignition also switches off the throttle control. There will then be no
unwanted battery discharge.
Power supply to the throttle control system via battery (term. 30 / 31)
Observe the manufacturer's safety measures when connecting the throttle control systems to the battery
voltage.
If the current consumption of the throttle control system in operating condition permanently amounts to
max. 3 A, terminals 30 (bat+), 31 (bat-) in the shipyard connector x4 (see section 24) can be used.
For the connection, see plan on page 132, connector X4 pin 1 (31-) and pin 2 (30+).
For connection to the power supply, use only the battery belonging to the engine.
NOTE
Low voltage and associated starting problems
Therefore:
S Disconnect the external throttle control system from the battery using the master switch when leaving
the ship for an extended period (of several days).
+ - - +
Electronic terminal box Stecker X9
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
(E-box)
A
Connector A for + -
throttle lever - +
to the electric
engine activation
Speed Bridge for the Input 4−20 mA for
output external engine activation
EDC throttle control
8 system
7
6 Rout 300
5 Umax 15V (idling)
4 Imax 48 mA (in the event of 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
Speed signal (out) 14V
(RL = 8 kW)
Duty cycle 50%
tmax = 500 s
21.1 General
Technical data
(1) E-box
(2) Emergency operating unit
(3) Connecting cable
The emergency operating unit is connected to connector X6 of the E-box or integrated into the existing
CAN bus, see also the appendix to this manual from page 209 under “System overview - CAN bus
system”.
Connecting cable
Emergency operating unit E-box
Socket PIN
L 40
Length (L) MAN item number Length (L) MAN item number
2m 51.25411-0025 25 m 51.25411-0027
10 m 51.25411-0026 30 m 51.25411-0032
15 m 51.25411-0015 40 m 51.25411-0001
20 m 51.25411-0016
ignition signal IN
starting interlock
starting interlock
emergency stop
ignition OUT
group alarm
group alarm
engine start
battery +
battery -
Horn
Horn
1 2 3 4 5 6 7 8 9 10111213141516
X4
Spannungsversorgung fuer
externe Fahrhebelsteuerung
Supply voltage for extern
bridge control
Maschinenraum
Engine room
- +
Horn
Groupalarm
(NC) Anschluss Startverblockung
connection starting interlock
battery charge 3W
30
Wheelhouse
Steuerstand
Ignition lock
Emergency
15 50 stop
battery charge 3W
Ladekontrolle 3W
Emergency
30
Anlassschloss
stop
Ignition lock
20K
Flybridge
15 50
20 kOhm Resistor
for wire breakage
monitoring
(termination)
ignition signal IN
starting interlock
starting interlock
emergency stop
ignition OUT
group alarm
group alarm
engine start
battery +
battery -
Horn
Horn
1 2 3 4 5 6 7 8 9 10111213141516
X4
Spannungsversorgung fuer
externe Fahrhebelsteuerung
Supply voltage for extern
Maschinenraum
bridge control
Engine room
- +
Horn
Groupalarm
(NC) Anschluss Startverblockung
connection starting interlock
Emergency
stop
Ignition
On/Off
battery charge 3W
Ladekontrolle 3W
Emergency
stop
Flybridge
20K
20 kOhm Resistor
for wire breakage
Engine monitoring
start (termination)
Ignition
On/Off
+24 V
+24 V 1
2 2
2 3 Start eng.
3
Start eng. 1 Ign. Out
2
3 3 4
ON OFF ON OFF
16 16
Ign. In Ign. In
X4
7
18 k
Emergency stop 1 Emergency stop 2
6
X4
10 HORN
isolated
contact MMDS + -
11
external power supply
(1) Engine display MMDS-CLC 6.5 (4) Electronic terminal box (E-box)
(2) Remote control MMDS-CLC R (5) CAN data line at connector X6
(3) Connection for further displays or VDO (6) Engine data, starboard engine
circular instruments; terminating resistor must (7) Engine data, port engine
be connected if no additional instruments are
used.
Seven languages are available for optimal adaptation to the operator's needs. English, German, Italian,
French, Spanish, traditional Chinese and simplified Chinese can be selected. Data can be displayed in
either metric or standard units.
The front of the display has a protection class of IP 67 and is thus sufficiently watertight for use on open
bridges. A UV-resistant plastic foil covering the entire front area protects the device and controls from
environmental influences and contamination. A photocell is integrated in the front plate of the display unit.
This detects the brightness of the environment and automatically adjusts the background lighting of the
display to existing conditions. As the ambient light decreases, the brightness of the display is reduced, and
with more light it is intensified. The brightness level of the automatic dimming feature can be adjusted using
the device to the operator's own requirements. In direct sunlight, the transflective display provides optimal
data readability.
To supplement the system, an identical display is also available which can indicate, via an additional CAN
bus, the tank capacity, fuel consumption, range and many other values.
23.4.1 Wiring of the colour displays 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
T-piece (1)
MAN item no. 51.25433-0023
Adapter for connecting additional VDO round instruments (MAN item no. 51.25411-6014)
A
G A
P H
B C
5
4 3
1 2
1 2 3
24.1.1 General
Technical data
General data
Dimensions, W x H x D: 70 x 130 x 65 mm
Console section, Bx H: 60 x 113 mm
Weight: approx. 0.5 kg
Environmental data
Operating temperature: -25 °C - +70 °C
Storage temperature: -30 °C - +85 °C
Protection class: IP 67 (front), IP 65 (rear)
Electrical data
Voltage supply: 9 - 32 VDC
Performance/power max. 400 mA
consumption:
Interfaces, cable end: 2x M12 circular connectors (socket, 8-pin)
Ignition release, cable end: 1 isolated relay contact, NO, 24 V DC/8A
(IGN-FREE)
24.2.1 General
Technical data
General data
Dimensions, W x H x D: 70 x 130 x 65 mm
Console section, Bx H: 60 x 113 mm
Weight: Approx. 0.5 kg
Environmental data
Operating temperature: -25 °C - +70 °C
Storage temperature: -30 °C - +85 °C
Protection class: IP 67 (front), IP 65 (rear)
Electrical data
Voltage supply: 9 - 32 VDC
Performance/power max. 400 mA
consumption:
Interfaces, cable end: 2x M12 circular connectors (socket, 8-pin) to EOP
2x M12 circular connectors (socket, 8-pin) to EOP D
24.3 Connecting cables for the Engine Operation Panels EOP and EOP D
Engine Operation Panel EOP E-box and EOP EOP D
14.5
L 40
25 Override system
NOTE
Danger of engine damage if alarms are ignored.
Therefore:
S The override system must only be used in emergencies. Remedy the cause of an alarm.
MAN refuses to accept liability for engine damage resulting from the use of the override system.
Connecting cable
Override button E-box
40 L 40
Assembly
26.2.1 Qualifications
WARNING
Risk of injury in case of inadequate qualification
Improper use can cause considerable personal injury and material damage.
Therefore:
S Only allow persons mentioned in the respective sections of this manual to carry out specific tasks.
In this manual, the following qualifications are specified for the various areas of activity:
S Instructed persons
have been instructed in a briefing about the tasks assigned to them and about the potential hazards of
improper conduct.
S Trained personnel
are, because of their technical training, knowledge, experience and awareness of the relevant
regulations, in the position to carry out the tasks assigned to them properly.
S Qualified electricians
are, because of their technical training, knowledge, experience and awareness of the relevant standards
and regulations, in a position to carry out work on electrical systems and to autonomously identify and
prevent possible hazards.
A qualified electrician has been trained for the specific operating site at which he/she will be working and
knows the relevant standards and regulations.
Only persons who are expected to perform their tasks reliably are permitted as personnel. Persons whose
responsiveness is affected, e.g. by drugs, alcohol or medication, are not permitted.
S In selecting the personnel, take account of the specific regulations relating to age and profession which
apply in the operating site.
WARNING
Danger for unauthorised persons
Unauthorised persons, who do not fulfil the requirements described here, are not aware of the hazards
in the working area.
Therefore:
S Keep unauthorised persons away from the working area.
S In case of doubt, approach these persons and instruct them to leave the working area.
S Stop work until any unauthorised parties have left the working area.
26.2.3 Instruction
Personnel must be instructed on a regular basis. The instruction must be logged to keep better track.
Hard hat
to protect against falling and flying parts.
Safety shoes
to protect against heavy falling parts and slipping on slippery surfaces.
Safety gloves
to protect the hands against friction, abrasions, cuts or more serious injuries as well
as contact with hot or corrosive parts or substances
Safety goggles
to protect the eyes from flying parts and splashing liquid.
Ear protection
to protect the ear from damage caused by noise.
Electrical current
DANGER
Risk of fatal injury due to electrical current
Contact with live parts causes a direct danger of fatal injury.
Damage to the insulation or individual components can mean danger to life.
Therefore:
S In case of damage to the insulation, switch off the power supply immediately and have repairs carried
out.
S All work on the electrical system must be performed by qualified electricians.
S When any work is carried out on the electrical equipment, disconnect it from the power and make sure
it is free of voltage.
S Before any maintenance, cleaning and repair work, switch off the power supply and secure it from
being switched on again.
S Do not bridge any fuses or put them out of operation. When replacing fuses, adhere to the correct
ampere rating.
S Keep moisture away from live parts. Moisture can lead to a short circuit.
Moving parts
WARNING
Risk of crushing due to moving components
Rotating and linearly moving components cause injuries.
For this reason:
S Follow the accident prevention regulations.
S Rotating machine parts to be provided with a suitable touch protection.
S Never remove protective equipments in front of the rotating components.
Exhaust gases
WARNING
Risk to health from exhaust gas system having leaks
Exhaust gases cause damage to health.
Therefore:
S Shut down engines with leaking exhaust gas systems immediately and repair them.
S Ensure adequate ventilation.
WARNING
Risk of fire from highly flammable materials
Highly flammable materials, liquids or gases can catch fire, causing serious or fatal injuries.
Therefore:
S Do not smoke in or near the danger zone.
Refrain from handling open flames or sources of ignition.
S Keep fire extinguisher ready.
S Immediately report any suspicious materials, liquids or gases to the person responsible.
S Cease work immediately in case of fire. Leave the danger zone until the all-clear signal is given.
WARNING
Risk of injury from harmful coolants
Coolants contain harmful substances. Contact with these substances can lead to serious poisoning,
allergies, skin irritation and damage to eyes.
Therefore:
S Observe the safety data sheets of the manufacturer.
S When handling coolants, always wear protective clothing, chemical-resistant gloves and protective
goggles.
S Avoid spilling and fogging.
WARNING
Risk of scalding by hot service products
Service products can reach high temperatures, causing burns in case of contact.
Therefore:
S Before handling service products, check whether they are hot. Allow to cool if necessary.
Hot surfaces
CAUTION
Risk of burns by hot surfaces
Contact with hot components can cause burns.
Therefore:
S Always wear protective clothing and gloves when working near hot components.
S Ensure before all tasks that all the components have cooled to room temperature.
Noise
WARNING
Damage to hearing due to noise
Noise levels arising in the working area can cause serious damage to hearing.
Therefore:
S Always wear ear protection while working.
S Only remain in the danger zone as long as necessary.
CAUTION
Risk of injury from edges and corners
Sharp edges and corners can cause abrasions and cuts on the skin.
Therefore:
S Proceed carefully when working near sharp edges and corners.
S If in doubt wear protective gloves.
CAUTION
Risk of tripping due to debris and objects lying around
Soiling and objects lying around are slip and trip hazards and can cause considerable injury.
Therefore:
S Always keep the working area clean.
S Remove any objects that are no longer required.
S Indicate trip hazards with yellow-black marker tape.
WARNING
Risk of injury by liquids flowing out
Liquids getting discharged under high pressure cause severe injuries.
Therefore:
S Have work done on the common rail system only by trained specialists.
S Shut down the engine and wait until the pressure has fallen before working on the common rail
system.
WARNING
Mortal danger from defective lines
Liquid jet gets released under high pressure.
Therefore:
S Never touch the liquid jet.
S Press the emergency stop button immediately.
S If necessary, initiate other measures in order to reduce the pressure and to stop the liquid jet.
S Absorb liquids that have leaked out properly and arrange for their disposal.
S Replace the defective parts.
WARNING
Risk of fatal injury due to strong magnetic fields
Therefore:
S Persons with pacemakers should not stay near the engine.
S Persons with metallic implants should not stay near the engine.
S Keep ferromagnetic materials and electric magnets away from the magnetic source (Minimum
distance 3 m).
S Put metallic objects (jewellery, watches and writing instruments, etc.) away before carrying out
maintenance work.
S Do not bring any electronic devices near the magnetic source.
S Do not bring any storage media, credit cards etc. near the magnetic source.
Electric welding
NOTE
Risk of material damage due to incorrect handling of welding equipment
Damage to components and the electronics system due to electric arc welding
Therefore:
S Connect “ANTIZAP SERVICE SENTRY” protection device (MAN item no. 80.78010-0002)
in accordance with the instructions accompanying the device.
S In case this device is unavailable, disconnect the batteries and
firmly connect the positive cable to the negative cable in order to make a 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 > 1 mm) and Positive
at the load-disconnecting relay load contacts. In addition, switch on many load consumers such as:
Starter switch (ignition) in driving position. The greater number of consumers that are switched on,
the greater the protection.
When welding is complete, first switch off all consumers,
remove all jumpered connections (reset to original condition) and 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 vessel.
WARNING
Risk of fatal injury due to non-functioning safety equipment
Safety equipment provides a maximum amount of safety during operation. Even if the safety equipment
complicates working processes, under no circumstances may they be disabled. Safety is guaranteed
only if the safety equipment is intact.
Therefore:
S Before beginning work, check whether all safety equipment is functional and correctly installed.
S Before starting the engine, check whether all safety equipment is functional and correctly installed.
WARNING
Mortal danger from inadequate protective devices
Therefore:
S Implement suitable protective devices before putting the engine into operation.
Preventive measures
S Always be prepared for accidents or fire.
S Keep first-aid equipment (first aid boxes, blankets, etc.) and fire extinguishers ready to hand.
S Check first-aid equipment and fire extinguishers for completeness and functionality on a regular basis.
S Familiarize personnel with accident signalling, first-aid and rescue equipment.
S Carry out safety briefings on a regular basis.
CAUTION
Accident despite all safety precautions
Despite all of the safety precautions, an accident may occur due to any of the following points.
Therefore, obtain medical assistance in case of:
S Contact with corrosive acid.
S Fuel penetrating the skin.
S Scalding by hot oil or coolant.
S Antifreeze splashing in eyes, etc.
26.7 Signage
Before putting vessel in operation, check whether the danger zones have been marked with signs.
WARNING
Risk of injury due to illegible symbols
Stickers and symbols can become dirty or otherwise unrecognisable in the course of time.
Therefore:
S Always keep all safety, warning and operating instructions in a clearly legible condition.
S Clean or replace illegible safety, warning and operating instructions
No trespassing
Areas designated in this manner may not be entered.
Electrical voltage
Only qualified electricians are allowed to work in working areas marked in this manner.
Unauthorised persons should not enter areas marked in this manner.
Hot surfaces
Hot surfaces, such as hot engines and hot fluids, are not always perceptible.
Do not touch them without protective gloves.
Risk of injury
If the instructions are not observed, there is a risk of injury.
CAUTION
Danger to the environment due to improper handling
Improper handling of environmentally hazardous materials , particularly in their disposal, can cause
considerable damage to the environment.
Therefore:
S Always observe the instructions below.
S If environmentally hazardous substances are accidentally released into the environment, take suitable
measures immediately. In case of doubt, inform the responsible local authority about the damage.
Lubricants
Lubricants such as greases and oils contain poisonous and environmentally hazardous substances. They
must not be released into the environment. They must be disposed of by a specialist waste disposal facility.
Diesel fuel
Diesel fuel contains poisonous and environmentally hazardous substances. It must not be released into
the environment. It must be disposed of by a specialist waste disposal facility.
Coolant
Coolants can contain poisonous and environmentally hazardous substances. They must not be released
into the environment. They must be disposed of by a specialist waste disposal facility.
DANGER
Falling loads can result in serious accidents!
Therefore:
S Use a crane lifting gear of sufficient size to lift an engine.
Ropes and chains must be properly attached on the crane hook.
The crane lifting gear, ropes and chains must be in perfect condition.
To lift the engine, 2 crane hook eyes (3) and (4) are attached to the engine.
Use a crane lifting gear (1) of sufficient size to lift an engine.
Ropes and chains (2) must exert a vertical pull (tolerance 5) on the crane hook.
DANGER
Falling loads can result in serious accidents!
Therefore:
S Use crane lifting gear.
The crane lifting gear, ropes and chains must be in perfect condition.
To lift the engine, 2 crane hook eyes (3) and (4) are attached to the engine.
Use a crane lifting gear (1) of sufficient size to lift an engine.
Ropes and chains (2) must exert a vertical pull (tolerance 5 ) on the crane hook.
DANGER
Falling loads can result in serious accidents!
Therefore:
S Use crane lifting gear.
The crane lifting gear, ropes and chains must be in perfect condition.
NOTE
Even the smallest of dirt particles in the fuel system lead to total failure of the injection system
Therefore:
S Ensure absolute cleanliness when carrying out work in the engine room.
S Provide fuel connections with caps.
NOTE
Moisture in the fuel system leads to total failure of the injection system
The engine is delivered from the factory with preservative and a closed fuel system (flow and return
lines).
Therefore:
S The fuel system must remain closed until start-up.
NOTE
Risk of material damage from couplings and attachments
Component damage due to incorrect crankshaft axial play.
Therefore:
S The crankshaft axial play of the engines defined by the design may not be reduced.
S Check the crankshaft axial play using a dial gauge fixed on a magnetic base.
Special tools
Special tools
NOTE
Damage due to vibrations and oscillations
Therefore:
S Check the alignment of the drive system annually or after approx. 3000 operating hours and correct
if necessary.
30.1.4 Testing the gearbox output and propeller shaft for radial offset
30.1.5 Checking the gearbox output and propeller shaft for angle offset
In order to obtain equal deflection angles in a V-configuration, an auxiliary device consisting of two
alignment rods can be used.
Such an auxiliary device is shown in the following.
With the given dimensions, this device can be used for propshafts with lengths of Lz = 700 to 1300 mm.
Shorter or longer propshafts require correspondingly shorter or longer rods A.
Procedure: Mount the alignment rods instead of the propshafts. Both parts must be equally long. Align the
engine/gearbox such that the tips of the alignment rods meet. Then remove the auxiliary device and mount
the propshafts.
31 Assembly of propshafts
NOTE
Vibrations in the driveline - damage to plain bearings and splines
Improperly assembled propshafts do not balance uneven drive loads, but reinforce them.
Therefore:
S Assemble propshafts in accordance with the manufacturer's instructions.
When connecting the two propshaft halves, ensure that the marks on the splined shaft and splined hub
(arrows) are facing each other.
Propshafts should be arranged such that the spline is as protected as possible from dust and moisture.
As a rule, this means installing the driveline according to the diagram below, where the spline seal points
downwards so that splashing water hitting it runs away from the spline.
Propshafts should not be separated at the splines and the halves interchanged, otherwise the quality of
balance will be greatly impaired. Balancing plates should not be removed for the same reason.
NOTE
Even the smallest of dirt particles in the fuel system causes total failure of the injection system.
Therefore:
S Ensure absolute cleanliness when carrying out work on the fuel system.
S Provide fuel connections with caps.
NOTE
Foreign particles and dirt in the engine cause engine damage
Therefore:
S When working on the exhaust system, no foreign bodies (bolts, washers etc.) may fall in the engine
S Before working any metal (cutting-off wheel, grinding disc), cover the engine with a tarpaulin
NOTE
Risk of material damage due to incorrect handling of welding equipment
Damage to components and the electronics system due to electric arc welding
Therefore:
S Connect “ANTIZAP SERVICE SENTRY” protection device (MAN item no. 80.78010-0002)
in accordance with the instructions accompanying the device.
S In case this device is unavailable, disconnect the batteries and
firmly connect the positive cable to the negative cable in order to make a 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 > 1 mm) and Positive
at the load-disconnecting relay load contacts. In addition, switch on many load consumers such as:
Starter switch (ignition) in driving position. The greater number of consumers that are switched on,
the greater the protection.
When welding is complete, first switch off all consumers and remove all jumpered connections (reset
to original condition) before connecting 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 vessel.
NOTE
Component damage caused by horizontal installation
Therefore:
S Install compensators as vertical as possible and securely support the continuing exhaust pipe.
S Observe the direction of exhaust flow through the compensator.
The exhaust system on the ship´s side shall be designed and fitted with exhaust gas compensators, that
length expansions > 10 mm must be prevented in direction of the engine. Expansions in lateral direction
must be prevented by suitable suspensions or by exhaust gas compensators.
Bolts/nuts with external or internal hexagonal bolt, head without collar or flange
Screws / nuts with outer hex or inner hex threads, head with collar or flange
35 Assembly drawings
346-348
382-383
E-box assembly
S Fasten the E-box vertically on a side wall of the engine room
S Mounting bolts M8
S Weight of the E-box: 8 kg
A clear area of 200 mm must be provided around the E-box for the plug.
42±0.3
50±1
70±1
80±0.3
Threaded bolt M4
Threaded rod M4
3.2-3.4
24.1-24.5
49
48
22.3-22.7
40 10 10
57 30
NOTE
Risk of malfunctions by incorrectly initial start -up can result in total loss of the engine
Therefore:
S Commissioning is done only by authorised personnel of MAN Nuremberg (Marine engines
department).
Reference
Information about Service products, refer to the MAN Approved Service Products.
https://my.manmn.com/portal/irj/asp
NOTE
Risk of engine damage due to incorrect oil level
Engine damage can result if the max. oil fill quantity is exceeded or fallen below.
Therefore:
S Determine the fill quantity of the oil sump attached to the engine. For the oil quantity of the oil sump,
see the table below.
NOTE
Engine damage due to dirt in the engine oil.
Therefore:
S Ensure absolute cleanliness while filling with engine oil.
ENVIRONMENTAL NOTE
Do not spill any engine oil while filling. Do not allow any engine oil to contaminate the soil or bodies
of water.
NOTE
Improperly marked oil dipsticks lead to incorrect oil filling and can lead to engine damage.
Therefore:
S Oil dipsticks are to be marked exclusively by personnel authorised by MAN Nuremberg (marine engine
department).
37.3.2 Electric oil change pump for engine and gearbox oil
38 Cooling system
The engine cooling system should be filled with a mixture of potable water and antifreeze based on
ethylene glycol or anti-corrosion agent.
For coolant preparation, see the publication “Service products for MAN industrial and marine diesel
engines”.
ENVIRONMENTAL NOTE
Do not spill any coolant while filling. Do not allow any coolant to contaminate the soil or bodies of water.
38.1.2 Opening the cooling system while the engine is at operating temperature
39.1.1 Check for correct filling with lubricating oil and coolant
NOTE
Engine damage due to missing operating fluids
Before starting the engine, ensure that:
S Lubricating oil has been filled, see page 197
S Coolant has been filled, see page 203
S The seacocks seawater pump have been opened
DANGER
Risk of fire due to diesel fuel
Diesel fuel is readily flammable.
Therefore:
S Do not smoke within the danger zone while refueling.
Refrain from handling open flames or sources of ignition.
S Only refuel when the engine is off.
S Pay attention to cleanliness.
S Do not spill any diesel fuel.
ENVIRONMENTAL NOTE
Do not spill any diesel fuel while filling. Do not allow any diesel fuel to contaminate the soil or bodies of
water.
NOTE
Improper of shutdown procedure leads to fault entries in the fault memory
(EDC/SFFR/MMDS) and can cause a reduction in engine speed.
Therefore:
S While the ignition is on, it is not allowed to switch off the power supply to the electronic diesel control
using the main battery switch.
Appendix
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
211
System overview - CAN bus system
212
Wiring of basic components
Vessel potential
(1) Starter
(2) 1st. Alternator
(3) 2nd. Alternator (optional)
(4) Terminal box
(5) Batteries for starter
(6) Batteries for additional onboard consumers
(7) Engine and geabox mounts
213
Wiring of basic components
214
Folders
40 Folders
40.1 Abbreviations
40.3 Index
A C
Accessibility, 23 Cooling system
Air filter, Intake air restriction, 58 Material selection, 74
Aligning the drive system, 171 pressurised system, 83
Alternator, 113 Schematic diagram, 69
Appendix, System overview, 209 - 233 Seacocks, 71
Applicability and validity, 11 Seawater intake, 70, 72
Assembly, 149 - 173, 193 - 217 Seawater lines, 71
Assembly drawings Seawater outlet, 72
Display MMDS-CLC 6.5, 187 Seawater strainer, 71
Display MMDS-CLC 8.8, 188 Crane transport
Electronic terminal box, 185 Engine with gearbox, 164
Emergency operating unit, 190 Engine without gearbox, 163
Engine Operation Panel - EOP, 189
Engine Operation Panel - EOP D, 189 D
Override button, 191 Display systems and instruments, System
overview, 137
Throttle control systems, 186
Assembly exhaust-gas compensator, 181 E
E-box, Wiring - system overview, 117
B
Elastic engine mounts, Height adjustment, 172
Bleeding the fuel system, 207
Electrics case
C Cabling - system overview, 117
Cabin heating, 105 Shipyard connector, 131
Connections, 106 Electronic terminal box, Connectors, 116
Heat output, 107 Electronic terminal box (E-box)
Schematic diagram, 105 Earthing, 117
Changes and modifications to the engine, 20 Installation, 115
Charge indicator lamp, 136 Emergency operating unit, 129
Checking the crankshaft axial play, 167 Installation, 129
Cleanliness Wiring, 130
Protection from dust, 165 Emergency stop, 135
Protection from moisture, 165 Emission control information label, 9
Colour display MMDS-CLC 6.5 Emission label, 11, 25
Displays, 138 Engine foundation, 36
Visualization, 139 Engine oil
Colour display MMDS-CLC 8.8, Displays, 140 Checking the engine oil level, 201
Colour displays MMDS-CLC, Wiring, 141 Determining the fill quantity, 197
Conduct in the event of a hazard, 159 Filling, 198
Coolant, 84 Oil quality, 197
E G
Engine Operation Panel, 143 Gearbox, connect at flange, 166
EOP, 143 Gearbox oil cooler, 73
EOP D, 145
EOP, installation, 144 H
EOP, wiring, 143 Hull cooling, 75
Engine operation panel D, Wiring, 145 Connections on the engine, 77
Engine room Diagram, 76
Accessibility of the engine, 30 Expansion tanks, 79
Air duct, 56 Thermodynamic configuration, 85
Air requirement, 54 Volumes, 79
Engine removal, 30 Hydraulic pumps, 109
Fans, 55
I
Temperature, 53
Inclination, 38
Ventilation, 53
Installation drawing, 11, 28
Engine weight, 37
Intake system, Diagram of turbocharging, 57
Environmental protection, 161
Exhaust back pressure J
Max. perm., 67 Jet drive, 100
Measurement, 67
Exhaust system L
Attachment, 63 Labeling, 22
Basic design concept, 61 Liability for material defects, 12
Exhaust outlet on the engine, 62
Seawater injection, 64 M
Structure, 62 Maintenance work, 23
Underwater outlet, 65 MAN Monitoring and Diagnostic System
(MMDS), 138
Exhaust-gas compensator, 180
Explanation of icons, 15 O
Oil pressure, Checking pressure build-up, 201
F
Operating ranges, 104
Filling fuel, 207
Override button, Connecting, 147
Fixed pitch propeller
Override system, Function, 147
Adjustment, 99
Maximum speeds, 100
Flange-mounted gearbox
Clutch, 46
Flywheel, 45
Torsional vibration analysis, 44
Flywheel, 50
Foreword, 9
Fuel lines, Assembly, 178
Fuel system
Fuel lines, 97
Permissible pressures, 97
Schematic diagram, 94
P T
Personal protective equipment, 153 Throttle control systems
Personnel, Requirements, 152 Actuation, 124
Planning, Installation of engine and gearbox, connecting cable, 121
17 - 41 External throttle control system, 123
Power take-off, 109 Internal throttle control system, 119
Propeller, Load indicator, 102 Terminating resistors, 121
Propeller system, 99 Torsional vibration analysis, 49
Fixed pitch propeller, 99
Proper use, 19 V
Propshafts V-drive, 48
Assembly, 177
W
General, 52
Warning device, acoustic, 136
R
Resilient engine mounts
Description, 41
Installation, 168
Resilient mounts
Engine and gearbox mounts, 42
Flange-mounted V-gearbox, 42
Responsibility of the operator, 151
S
Safety equipment, 20, 158
Seawater pump, Supply quantities, 72
Signage, 160
Spare parts, 13
Special risks, 154
Standards, 14
Start interlock, 126
Start-up
Filling coolant, 203
Important information, 195
Lubricating oil system, 197
Pouring in engine oil, 197
Start/stop device, 134
Starting and stopping the engine, 207