51.99493-8578“Translation of the original operating instructions”
Information and Copyright
Subject to technical alterations in the interests of further development.
Reprinting, copying or translating of these instructions, even in part, is forbidden without written permission
from MAN. All legal copyrights remain the exclusive property of MAN.
these Operating Instructions are intended to familiarize you with your new MAN Diesel engine and how it
operates.
This manual is supplemented by the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines"
and the “Service record book".
Note:
All three publications belong to the engine and must always be kept ready to hand near the en
gine in the engine room.
Comply in full with instructions relating to operation, prevention of accidents and environmental
protection.
MAN Diesel engines are developed and manufactured in line with the latest state of the art. However,
trouble-free operation and high performance can only be achieved if the specified maintenance intervals
are observed and only approved fuels, lubricants and coolants are used.
Note:
Only use fuels, lubricants etc. in accordance with MAN's regulations.
Otherwise the manufacturer's liability for defects will not apply!
For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN
Diesel Engines".
You can find the approved products in the internet under:
https://mmrepro.mn.man.de/bstwebapp/BSTServlet
It is imperative and in your own interest to entrust your MAN Local Service Centre with the removal of any
disturbances and with the performance of checking, setting, and repair work.
Yours faithfully,
MAN Truck & Bus AG
Werk Nürnberg
4
Instructions
Important instructions which concern technical safety and protection of persons are emphasised as shown
below.
Danger:
This refers to working and operating procedures which must be complied with in order to rule out
the risk to persons.
Caution:
This refers to working and operating procedures which must be complied with in order to prevent
damage to or destruction of material.
Note:
Explanations useful for understanding the working or operating procedure to be performed.
5
Declaration
6
Nameplates
In all your correspondence please always quote en
gine model, serial number and job number (Order
number).
For this reason it is advisable to read off the data
from the engine type plates before putting the engine
into operation and to enter them in the appropriate
spaces.
The engine type plates are on the crankcase (see
illustration).
MAN Nutzfahrzeuge AktiengesellscMAN Nutzfahrzeuge Aktiengesellschaft
Nürnberg Works, Germany
Job NoRating kW
Power kWWorks No.
:
Engine No.TypeYear of manufacture.
Eng. speed 1/min
Operating altitude m uNNPower. PS
:
Speed rpm
:
Altitude mRating BHP
7
Serial NoModelYear
−0219
Safety regulations
General notes
Handling diesel engines and the necessary resources is no problem when the personnel commis
sioned with operation and maintenance are trained accordingly and use their common sense.
This summary is a compilation of the most important regulations. These are broken down into main sec
tions which contain the information necessary for preventing injury to persons, damage to property and pol
lution. In addition to these regulations those dictated by the type of engine and its site are to be observed
also.
Important:
If, despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel penetrat
ing the skin, scalding from hot oil, anti‐freeze being splashed in the eyes etc., consult a doctor immedi
ately.
1. Regulations designed to prevent accidents with injury to persons
During commissioning, starting and operation
D Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the “critical" points. If you are unsure, ask your
MAN representative.
D For reasons of safety we recommend you attach a notice to the door of the engine
room prohibiting the access of unauthorized persons and that you draw the attention of
the operating personal to the fact that they are responsible for the safety of persons
who enter the engine room.
D The engine must be started and operated only by authorized personnel.
Ensure that the engine cannot be started by unauthorized persons.
D When the engine is running, do not get too close to the rotating parts. Wear close‐fitting
clothing.
D Do not touch the engine with bare hands when it is warm from operation - risk of burns.
D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel
engines which are to be operated in enclosed spaces. Ensure that there is adequate
ventilation and air extraction.
D For safety reasons a separate, functioning red emergency‐stop‐button for each
engine must be installed at every bridge (the engine must stop immediately when
the button is pressed once).
8
Safety regulations
ËË
ËË
D Electrical accessories and equipment from other manufactures may only be
connected without the approval of MAN to the connections provided for the cu
stomer or shipyard.
The control of the engine may be adversely affected and thus may lead to property
damage or personal injury and is therefore not permitted.
MAN assumes no liability for any property damage or personal injury.
Connections to the following MAN components are prohibited:
-EDC engine control unit (K-Line, CAN-Bus)
-MAN internal or external throttle lever control system (CAN-Bus)
-Emergency steering control (serial, CAN-Bus)
-Display systems for alarms (serial, CAN-Bus)
Approved connectors on terminal box: X4, X8 and X9.
D Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
During maintenance and care
D Always carry out maintenance work when the engine is switched off.
If the engine has to be maintained while it is running, e.g. changing the elements of
change‐over filters, remember that there is a risk of scalding. Do not get too close to ro
tating parts.
D Change the oil when the engines is warm from operation.
Caution:
There is a risk of burns and scalding. Do not touch oil drain plugs or oil filters with bare
hands.
D Take into account the amount of oil in the sump. Use a vessel of sufficient size to en
sure that the oil will not overflow.
D Open the coolant circuit only when the engine has cooled down.
If opening while the engine is still warm is unavoidable, comply with the instructions in
the chapter entitled “Maintenance and Care".
D Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any ad
ditional hydraulic oil circuit) during the operation.
The fluids which flow out can cause injury.
D Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be
filled only when the engine is switched off.
D When using compressed air, e.g. for cleaning the radiator, wear goggles.
D Keep service products (anti‐freeze) only in containers which can not be confused with
drinks containers.
9
Safety regulations
D Comply with the manufacturer's instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.
2. Regulations designed to prevent damage to engine and premature wear
Do not demand more from the engine than it is able to supply in its intended application. Detailed informa
tion on this can be found in the sales literature.
If faults occur, find the cause immediately and have it eliminated in order to prevent more serious damage.
Use only genuine MAN spare parts. MAN will accept no responsibility for damage resulting from the install
ation of other parts which are supposedly “just as good".
In addition to the above, note the following points:
D Never let the engine run when dry, i.e. without lube oil or coolant.
D When starting do not use any additional starting aids (e.g. injection with starting pilot).
D Use only MAN‐approved service products (fuel, engine oil, anti‐freeze and anti‐corrosion agent). Pay at
tention to cleanliness. The Diesel fuel must be free of water. See “Maintenance and care".
D Have the engine maintained at the specified intervals.
D Today modern components of diesel injection consist of high‐precision parts which are exposed to ex
treme stresses. The high‐precision technology requires the utmost cleanliness during all work on the
fuel system.
Even a particle of dirt over 0,2 mm can lead to the failure of components.
D Do not switch off the engine immediately when it is warm, but let it run without load for about 5 minutes
so that temperature equalization can take place.
D Never put cold coolant into an overheated engine. See “Maintenance and care".
D Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.
Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered to.
D Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, coolant tem
perature) function satisfactorily.
D It is advisable to switch off the engine if an alarm of any kind is displayed in the engine monitoring and
diagnostic system. If this is not possible for any reason, the engine should be run no faster than 1200
rpm until the fault is remedied, see page 24.
D Comply with instructions for operation of the alternator. See “Maintenance and care".
D Do not let the seawater pump run dry. If there is a risk of frost, drain the pump when the engine is
switched off.
10
Safety regulations
3. Regulations designed to prevent pollution
Engine oil and filter elements / cartridges, fuel / fuel filter
D Take old oil only to an old oil collection point.
D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
Caution:
The drinking water supply could be contaminated.
D Filter elements are classed as dangerous waste and must be treated as such.
Coolant
D Treat undiluted anti‐corrosion agent and / or anti‐freeze as dangerous waste.
D When disposing of spent coolant comply with the regulations of the relevant local authorities.
4. Notes on safety in handling used engine oil ∗
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, irrit
ation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances
which have caused skin cancer in animal experiments. If the basic rules of hygiene and health and safety
at work are observed, health risks are not to the expected as a result of handling used engine oil.
Health precautions:
D Avoid prolonged or repeated skin contact with used engine oil.
D Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
D Clean skin which has been in contact with engine oil.
-Wash thoroughly with soap and water. A nailbrush is an effective aid.
-Certain products make it easier to clean your hands.
-Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
D After washing apply a fatty skin cream to the skin.
D Change oil‐soaked clothing and shoes.
D Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly
- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are
punishable.
Collect and dispose of used engine oil carefully. For information on collection points please contact the
seller, the supplier or the local authorities.
∗ Adapted from “Notes on handling used engine oil".
11
Safety regulations
5. Special instructions when working on the common rail system
Accident protection
D Risk of injury!
Fuel jets can cut through skin.
The atomisation of fuel creates a fire risk.
-When the engine is running never loosen the screw connections on the fuel's
high‐pressure side of the common rail system (injection line from the high‐pressure
pump to the rail, on the rail and on the cylinder head to the injector)
-Keep away from the engine when it is running
D Risk of injury!
When the engine is running the lines are constantly under a fuel pressure of up
to 1600 bar.
-Wait at least a minute until the pressure in the rail has dropped before loosening a
screw connection
-If necessary check the pressure drop in the rail with MAN‐Cats
D Risk of injury!
-People with pacemaker must keep at least 20 cm away from the running engine.
-Do not touch live parts on the electric connection of the injectors when the engine is
running.
Cleanliness
Today modern components of diesel injection consist of high‐precision parts which are exposed to extreme
stresses. The high‐precision technology requires the utmost cleanliness during all work on the fuel sys
tem.
Even a particle of dirt over 0,2 mm can lead to the failure of components.
The measures described as follows are therefore essential before work begins:
Risk of damage from penetration of dirt!
D Before working on the clean side of the fuel system clean the engine and the engine
compartment. During cleaning the fuel system must be closed.
D Carry out visual inspection for any leakage or damage to the fuel system
D Do not spray the high‐pressure cleaner direct onto the electric components, or alternati
vely keep them covered
D Do not carry out any welding or sanding work in the engine compartment during mainte
nance / repair
12
Safety regulations
D Avoid air movements (any swirling of dust when starting engines)
D The area of the still closed fuel system must be cleaned and dried with the aid of com
pressed air
D Remove detached particles of dirt such as paint chippings and insulation material with a
suitable extractor (industrial type vacuum cleaner)
D Cover areas of the engine compartment from which dust particles could be detached
with clean foil
D Wash your hands and put on clean work clothes before starting the disassembly work
When carrying out the work it is essential to comply with the following measures:
Risk of damage from penetration of dirt!
D When the clean side of the fuel system has been opened it is not permissible to use
compressed air for cleaning
D During assembly work loose dirt must be removed with the aid of suitable extractors (in
dustrial type vacuum cleaners)
D Use only fluff‐free cleaning cloths on the fuel system
D Clean tools and working materials before starting to work
D Only tools without any damage may be used (cracked chrome coatings)
D When removing and installing components do not use materials such as cloths, cardbo
ard or wood since these could shed particles and fine fibres
D If any paint chips/flakes off when connections are loosened (from possible over‐coating)
these chippings must be carefully removed before finally loosening the screw connec
tion
D The connection openings of all parts removed from the clean side of the fuel system
must be immediately closed up with suitable caps/stoppers
D These caps/stoppers must be packed protected from dust prior to use and after being
used once they must be disposed of
D Following this all the components must be carefully stored in a clean, closed container
D Never use used cleaning or testing liquids for these components
D New parts must not be removed from their original packing material until directly before
use
D Work on removed components may be carried out only at a workplace specially equip
ped for it
D If removed parts are shipped always use the original packing material of the new part
When putting a new or overhauled engine into operation for the first time pay attention to the “Installation
instructions for MAN marine diesel engines" without fail.
It is recommended that new or overhauled engines should not be operated at a load higher than about 75%
maximum load during the first few hours of operation. Initial run-in should be at varying speeds. After this
initial run-in, the engine should be brought up to full output gradually.
Caution:
Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc."). Otherwise the liab
ility for defects will become null and void!
Filling with fuel
Caution:
Fill the tank only when the engine is switched off. Pay attention to cleanliness. Do not spill fuel.
Use only approved fuels, see brochure Fuels, lubricants etc.".
Filling-in of coolant
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze agent on the
ethylene glycole basis or anti-corrosion agent.
See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines".
D Pour in coolant slowly via expansion tank, see page 110
D Coolant filling quantity - see “Technical data", from page 101
20
Commissioning and operation
Seawater pump
Do not let seawater pump run dry!
Make sure that all valves / cocks in the seawater
circuit are open.
If there is a risk of frost, drain the seawater pump.
Refilling with oil
The engines are as a rule supplied without oil.
Pour oil into engine via filler neck, see page 103.
Caution:
Do not add so much engine oil that the oil
level rises above the max. marking on the
dipstick. Overfilling will result in damage
to the engine.
Oil filling quantity - see “Technical data", from
page 101.
21
Commissioning and operation
Commissioning
Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if neces
sary.
Caution:
Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc."). Otherwise the liab
ility for defects will become null and void!
Checking oil level
Check engine oil level only approx. 20 minutes
after the unit has been switched off.
DPull out dipstick (arrow)
D wipe it with a clean, lint-free cloth
D and push it in again up to the stop
D Pull out dipstick again
The oil level should be between the two notches in
the dipstick and must never fall below the lower
notch.
Caution:
Do not add so much engine oil that the oil
level rises above the max. marking on the
dipstick. Overfilling will result in damage
to the engine.
Ensure utmost cleanliness when handling fuels,
lubricants and coolants.
Oil
?
MAX
MIN
22
Commissioning and operation
Starting
Danger:
Before starting make sure that no-one is in the engine's danger area.
Caution:
When starting do not use any additional starting aids (e.g. injection with starting pilot).
There are two possibilities to start the engine: using the ignition lock or using the Start" button.
Starting via the ignition lock:
Ensure that the gearbox is in neutral.
Insert the ignition key and turn it to position I". Readiness for operation is indicated by an indicator lamp
lighting up.
Turn ignition key on until stop (position “III" depending on starter lock) starter is activated.
Lube oil pressure must build up at the oil pressure gauge. If it does not, switch off the engine immediately.
Do not operate starter for longer than 10 seconds at a time.
After ignition of the engine, release the starter button and adjust control lever for desired speed.
If engine fails to start, release the key, wait about 30 seconds, then operate starter again.
For repeated starting turn the key back to “0".
If the engine is kept idling for long periods it may cool down and thus start to emit white or blue smoke.
We therefore recommend that you do not let the engine idle for more than 5 minutes.
It is well known that with any internal combustion engine wear is higher during idling.
Prolonged idling is harmful to the environment.
Starting via the button:
Ensure that the gearbox is in neutral.
Press the “IGN ON/OFF“ button. Readiness for operation is indicated by an indicator lamp lighting up.
Actuate “Engine Start“ button. Starter runs up and the control light goes out.
Lube oil pressure must build up at the oil pressure gauge on the display. If it does not, switch off the engine
immediately.
Do not operate starter for longer than 10 seconds at a time.
After starting the engine, let go of the Start button and set the adjustment lever to the desired speed.
If the engine has not started, wait approx. 30 seconds before pressing the Start" button again to operate
the starter motor.
If the engine is kept idling for long periods it may cool down and thus start to emit white or blue smoke.
We therefore recommend that you do not let the engine idle for more than 5 minutes.
It is well known that with any internal combustion engine wear is higher during idling.
Prolonged idling is harmful to the environment.
23
Commissioning and operation
Operation monitoring system
Caution:
Do not exceed the maximum permissible engine tilt. If faults occur, find their cause immediately
and have them eliminated in order to prevent more serious damage!
If an engine / gearbox alarm is displayed on the monitoring devices, the engine is to be turned off
or, i.e. operated at low load at max. 1200 rpm.
When the following alarms are displayed
-engine oil pressure / reduction of lubrication oil pressure
-engine coolant temperature / overheating of engine coolant
-engine charge-air temperature
the engine is to be turned off immediately and the cause of the fault properly remedied, i.e. in a
specialist workshop.
Do not put this engine into operation again until the fault has been eliminated.
The engine is equipped as series standard with a monitoring and diagnostic system MAN-Marine-Dia
gnose-System (MMDS.
On the control console and alternatively on other control consoles, the following display devices are avail
able for monitoring operation:
1. Engine room panel, see page 26
CAN bus-controlled display devices:
2. CAN-Bus round instruments, see page 29
3. Display device MMDS-CLC 6.5, see page 33
4. MMDS-CLC 6.5 ship's alarm display, see page 48
Display units supported by PC:
5. Display device MMDS-CMS, see page 55
For operation and speed adjustment, MAN provides the following equipment:
6. Drive lever control system Marine Power Control (MPC), see page 75
6.1.Mobile navigating console, see page 88
7. Optional: emergency unit Em (Emergency), see page 92
7.1.Override button for MMDS-CR and MMDS-BE3 systems, see page 96
24
Commissioning and operation
Differences in operating parameters of engines and gearboxes
Differences in parameters can be observed on identical engines, irrespective if they are installed in one
boat or in different boats (boat series), such as
D pressures
D temperatures
D speeds
D fuel consumption
D injection quantity
D Load
D relative load
D control head signal
D oil level of engine and gearbox
D engine coolant level
D battery and charging voltage
The same applies to a single V-engine (e.g. exhaust temperatures before turbine, l.h. and r.h. side cylinder
banks).
These differences may be caused by
D component tolerances of the mechanical and electrical engine components
D design-related influences on engines (this applies especially to the exhaust temp.)
D external influences such as fuel supply, air supply and coolant supply
D installation conditions, hull characteristic and flow, exhaust system
D differences in the propeller and stern gear.
Under normal conditions this does not have any negative impact on the engine's operating safety. If the op
erating parameters are in an impermissible range, this is indicated by appropriate alarms of the diagnostic
system.
The same applies to the gearbox parameters.Please note that especially differences in the oil temperature
may arise on gearboxes running in clockwise or anticlockwise direction.
The engine room panel is optionally available and serves to display engine and gearbox data, as well as
system information. In order to obtain the full functionality of an engine room panel, as well as the display
additional function buttons are integrated for the control of the ignition. starting the engine and for engine
speed adjustment.
5
1
4
2
3
(1) Set +
(2) Set -
(3) Emergency stop
Function “Ignition ON/OFF" (5) (yellow button)
After activated ignition at the control console, the ignition in the engine room is switched on and off with the
yellow buttons “IGN ON/OFF" (5).
If the ignition is not activated at the bridge or flybridge, the button has no function.
(4) Start
(5) ING (Ignition)
Activation of the ignition is indicated by the internal yellow lighting of the button. Only when the ignition has
been activated at the bridge is the yellow button “IGN ON/OFF" (5) of the engine room panel enabled.
Caution:
Ignition off ⇒ engine stop
26
Commissioning and operation
Function “Start" (4) (green button)
With the ignition switched on, the engine can be started by pressing the green button “Start" (4).
The button lights up green when the ignition is switched on.
Function “Stop" (5) (yellow button)
Actuation of the yellow button “IGN ON/OFF" (5) stops the engine.
Function “Emergency stop“ (3)
Pressing the emergency stop switch (3) in the cover of the terminal box shuts the engine down immedi
ately. To unlock the emergency stop switch (3), turn the cap of the switch clockwise.
Then the ignition must be switched off and on again, in order to restart the engine.
Engine speed adjustment:
Function “Set +" (1)
By actuating the button “Set +" (1) with the engine running, the engine speed is increased.
Function “Set -" (2)
By actuating the button “Set -" (2) with the engine running, the engine speed is reduced.
Activation of the intermediate speed function:
Press “Set +" and “Set -" simultaneously, until both buttons flash.
To confirm, press both buttons again. Both buttons now light continuously.
Deactivation of the intermediate speed function:
By actuating the yellow button “IGN ON/OFF" (5) the intermediate engine speed function is terminated.
The intermediate engine speed function is carried out in similar fashion on the emergency unit, see
page 92.
27
Commissioning and operation
Optional
External LC display of the ship-vehicle management computer (SFFR) in the cover of the engine
terminal box
Alarms and their codings can be indicated via the external LC display of the ship-vehicle management com
puter and communicated to our customer service organisation.
If an active MMDS alarm occurs the corresponding MMDS alarm page will be indicated automatically and
can be exited only after confirmation.
Flashing light , Indication of EDC, SFFR fault with high priority.
Permanent light, Indication of EDC, SFFR fault with low priority.
Flashing light Active, non-confirmed MMDS alarm
Permanent light Active, confirmed MMDS alarm
Operation of the external LC display of the ship-vehicle management computer
Operating button for calling up menu if no active, non-confirmed MMDS alarm is indic
ated.
For navigating in the menu, for indicating next or previous fault.
Confirmation of selection.
Acoustic acknowledgement of all monitoring devices connected to the same CAN bus.
For visual acknowledgement of an MMDS alarm.
For sending a resetting signal to the central MMDS unit.
28
Commissioning and operation
CAN bus-controlled display devices:
2. CAN-Bus round instruments, rev counter with information display and buttons
D Rev counter (0-3000 rpm) with integrated LCD display for the following parameters and buttons for pa
ging:
-Engine oil pressure
-Gearbox oil pressure
-Coolant temperature
-Engine oil temperature
-Engine exhaust temperature
-Charge air temperature
-Boost pressure
-Load
-Hours of operation
-Fuel consumption
-Battery voltage
D Oil pressure engine0-10 bar
D Gearbox oil pressure0-25 bar
D Oil temperature engine50--150°C
D Coolant temperature engine40-120°C
D Exhaust temperature engine100-900°C
D Battery voltage 18-32 V
29
Commissioning and operation
Tachometer CAN-Master
The VDO Ocean Link Tachometer (CAN-Bus Tachometer)
The VDO Ocean Link tachometer is a multifunctional instrument for
indicating engine data, and is intended for use in navigation of sports
ships. The tachometer shows the actual engine speed in operation,
on the analogue scale. Further values and operating aids appear in
the LC display.
The instrument has a push-button on the front side, with which all
the functions can be selected. Handling of the instrument is thus
easy and uncomplicated.
LC‐DisplayPush button key
Main Functions
The main functions of the VDO Ocean Link can be called up by pressing the push-button. Each time the
button is pressed, the next measured value is displayed.
-Engine oil pressure-Charge air temperature
-Gearbox oil pressure - Charge air pressure
-Coolant temperature-% Load
-Engine oil temperature - Running time
-Exhaust gas temperature b. turbine 1-Current fuel consumption
-Exhaust gas temperature b. turbine 2-Battery voltage
-Exhaust gas temperature after turbine
The exhaust temperature to be displayed must be set when the display messages (Screen on / off).
30
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