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Manual de Plan de Mantto. D2676LE434

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0% found this document useful (0 votes)

107 views116 pages

Manual de Plan de Mantto. D2676LE434

Uploaded by

MAYINN

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Maintenance Manual

MAN marine diesel engines

Non-classified

D2676 LE4..

51.99597-8070 “Translation of the original instructions”

Version 01
Imprint

We reserve the right to make technical modifications in the course of further development.
Not to be reprinted, duplicated by any means whatsoever or translated - in whole or in part - without
the prior written approval of MAN. All rights deriving from copyright law are expressly reserved by MAN.

 2016
MAN Truck & Bus AG
Vogelweiherstrasse 33
90441 Nuremberg
Germany
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1932
E-Mail: [email protected]
Internet: www.man-engines.com

Technical status as on: 01/2016

51.99597-8070

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
2 and the safety notes in all the chapters.
Table of contents

1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information about the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.1 Publications belonging to the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.2 Supplementary publications for the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Explanation of icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Limitation on liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8 Warranty provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Contents of the maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Modifications and conversions to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Requirements of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.1 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.2 Unauthorised persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.3 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.9 Conduct in case of hazards and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.10 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.11 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Purpose of this maintenance instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Scope of warranty for the basic engine (base engine warranty) . . . . . . . . . . . . . . . . . . . . . . 27
3.3 US regulations (3.3.1 & 3.3.2 ► US only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.1 Emission behaviour of the engine for commercial engines
(emission warranty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.2 Emission behaviour of the engine for recreational engines
(emission warranty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 Carrying out maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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. 3
Table of contents

4 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 General information on doing maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5 Service products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Maintenance work according to operating hours for commercial engines . . . . . . . . . . . . . . 30

5.1 Light Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Medium Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6 Maintenance work according to operating hours for recreational engines . . . . . . . . . . . . . 33

6.1 Light Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7 Maintenance according to time intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8 Scope of the maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9 Instructions on maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.3 Instructions on doing maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.4 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.4.1 Engine cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.4.2 Change air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.4.3 Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.4.4 Cleaning the fuel pre-filter with hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.4.5 Fuel pre-filter with water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.4.6 Changing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.4.7 Ventilating the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.4.8 Changing the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.4.9 Changing the ribbed V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.4.10 Checking the valve clearance and adjusting it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.5 Checking the exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.6 Checking the cable connection and connector for tight fit . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
4 and the safety notes in all the chapters.
Table of contents

10 Troubleshooting and diagnostics with MAN-cats® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

10.1 Using MAN-cats® in maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.2 Instructions on use of MAN cats® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.3 Performing diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.3.1 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.3.2 Rev-up test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.3.3 High-pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.3.4 Meaning of symbols when reading out the diagnostic memory . . . . . . . . . . . . . . . . . 73

11 Taking out of operation and returning to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

11.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

12 Taking the engine out of operation temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

12.1 Taking the engine out of operation for up to 3 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
12.1.1 Taking the engine out of operation for between 3 to 6 months . . . . . . . . . . . . . . . . . . 76
12.1.2 Preserving agent for the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
12.1.3 Preserving the intake and exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
12.2 Restarting engines that have been shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
12.2.1 Putting preserved engines into operation according to the M 3069 MAN works
standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
12.2.2 Starting up non-preserved engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
6 and the safety notes in all the chapters.
Foreword

1 Foreword
Read carefully and become familiar with the information in your Maintenance Manual of your MAN engine.
The Maintenance Manual describes procedures, helpful tips and schedules for maintenance and care
which can extend the life of your engine.
This maintenance manual apply to the following Application types:

Application type Engine type

Light Duty D2676 LE4X3

Medium Duty D2676 LE4X2

Medium Duty D2676 LE4X5

Heavy Duty D2676 LE4X1

Heavy Duty D2676 LE4X4

The respective application type "Light Duty", "Medium Duty" or "Heavy Duty"
is specified by the last digit of Engine type, which is recorded on the number plate of the engine.
A clean environment is of concern to all of us.
MAN has built into your high speed diesel marine engine efficient emission parts, using genuine MAN parts,
in conformance with the Federal Clean Air Act in the United States.
To help keep our air clean, you can do your part by having your engine maintenance services and all
repairs performed in a timely manner.
This Maintenance Manual describes the work on the basic engine as well as on the emission-related
engine components.
The prerequisite for complying with the guaranteed emission values is, among others, complying with the
maintenance specifications given in this manual.

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. 7
Foreword

1.1 Information about the maintenance manual

This maintenance manual contains a maintenance schedule, important instructions on maintenance and
the maintenance records. The requirement for working safely is to follow all instructions on safety and work.
Moreover, the local accident prevention regulations applicable and general provisions on safety for the
application area of the engine must be followed.
Timely and conscientious maintenance and care at the specified service intervals ensure and maintain the
operating safety, as well as its reliable use of your engine.
The maintenance schedule provides information about the maintenance intervals and specifies the type of
maintenance work to be done. Each maintenance must be acknowledged on the associated maintenance
record given in the Appendix of this manual.
Use only original MAN service products, spare parts and accessories or those that have been approved by
MAN.
Only original replacement parts that we have approved have been specially tested by us to ensure their
reliability, safety and suitability for use in the engine.

1.1.1 Publications belonging to the maintenance manual

The following publications belong to the maintenance manual
- Service products for MAN diesel engines
- Operator's manual
These publications are parts of the product and must be kept near the engine so that they can be reached
by the personnel whenever required.
Read the maintenance manual carefully before starting any work!

1.1.2 Supplementary publications for the engine

The following manuals are available as a supplement to the maintenance manual for the engine:

For the operator and the maintenance and service personnel

- Spare parts catalogue (included in the scope of supply)

For the service personnel

- Repair manual

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
8 and the safety notes in all the chapters.
Foreword

1.2 Explanation of icons

Warnings
Warnings in this operator's 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.

Tips and Recommendations

Tip for users

Tips and recommendations as well as information for efficient and trouble-free operation.

ENVIRONMENTAL NOTE
Tips on conduct for environmental protection.

General information
• This symbol indicates a listing at the first level.
- This symbol indicates a listing at the second level.
► This symbol indicates an action / sequence of actions.
(1) This symbol indicates an item of a graphic display in the text.
[1] This symbol indicates an item of a special tool in the text.

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. 9
Foreword

1.3 Limitation on liability

All information and instructions in this manual have been compiled taking into consideration the applicable
standards and regulations, the state-of-the-art technology as well as our knowledge and experience
acquired over a period of several years.
MAN does not assume any liability for damage caused as a result of:
S Disregarding this manual
S Improper use
S Use of untrained personnel
S Unauthorised conversions
S Technical modifications
S Use of non-approved spare parts and service products
S By damage or malfunctions due to lack of maintenance
S Damage or malfunctions due to misuse, negligence, accident or fire
S Crash parts repaired due to damage in a collision
In case of special designs, the actual scope of supply, the use of additional ordering options or on account
of the latest technical modifications may vary from the explanations and illustrations described here.
The obligations given in the supply agreement and the general terms and conditions of MAN, and the
statutory regulations valid at the time of concluding the contract shall be applicable.
Your dealer will deny warranty coverage unless you present to the dealer proof in the form of service or
repair orders that all scheduled maintenance was performed in a timely manner.

1.4 Copyright protection

Handle the manual confidentially. It is meant only for those working with the engine.
It is prohibited to provide the manual to third parties without the written consent of MAN.

Tip for users

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.

1.5 Other applicable documents

Installed in the engine and suppliers' components (e.g. injection system). The respective suppliers of these
supplied components have carried out risk assessments for them.
The compatibility of the design with the European and national regulations applicable has been declared by
the respective suppliers of the components.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
10 and the safety notes in all the chapters.
Foreword

1.6 Spare parts

Maintenance, repair or replacement of spare parts may be performed by any authorized service and repair
establishment, without affecting the emission parts, provided that such repairs are performed to
manufacturers specifications, and that replacement parts are at least equivalent to genuine MAN parts in
emission performance and durability. Warranty repairs and replacements, however, must be performed by
an authorized MAN dealer.
We recommend that you use only original MAN spare parts and accessories or those that have been
approved by MAN. Only original replacement parts that we have approved and have been specially tested
by us to ensure their reliability, safety and suitability for use in the engine.
If other than genuine MAN replacement parts are used, the owner should make sure that such parts are
warranted by their manufacturer and that they are at least equivalent to genuine MAN replacement parts in
emission performance and durability. We can not assess this for other products despite on-going market
observation and we can not certify the same.

WARNING
Risk of injury caused by wrong spare parts!
Wrong or defective spare parts may lead to damage, malfunction or total failure and it may affect
the safety.
Therefore:
S Recommendation: Use only original MAN spare parts

Tip for users

Please mention the engine type, engine number and the order number with all communication,
see the operator's manual.

Order spare parts from the authorised dealer or directly from MAN.
Address, see page 2.

1.7 Disposal
Arrange for disposal in accordance with national regulations.
Send dismantled or disassembled components for recycling provided that there is no agreement on
sending them back or arranging for their disposal:
S Sort metallic parts and scrap them
S Send plastic elements for recycling
S Dispose of other components according to the material properties

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. 11
Foreword

1.8 Warranty provisions

The obligations given in the supply agreement and the general terms and conditions of MAN,
and the statutory regulations valid at the time of concluding the contract shall be applicable.
Ignoring this manual leads to warranty claims becoming null and void.
If you use parts that are not approved, warranty claims shall become null and void.
We recommend that you use original parts even after the expiry of the warranty period in order to ensure
consistent performance of the engine.
This warranty does not cover the replacement of filters, oil, lubricants or fluids unless their replacement is a
necessary part of engine related warranty on a covered component.
This warranty does not cover the cost of parts and labor involved in any scheduled maintenance service.
Scheduled maintenance services are described in the maintenance section of this booklet.

1.9 Customer service

The MAN customer service is at your disposal for technical information.

Tip for users

Please mention the engine type, engine number and the order number with all communication,
see the operator's manual.
Order spare parts from the authorised dealer or directly from MAN.
Address, see page 2.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
12 and the safety notes in all the chapters.
General safety instructions

2 General safety instructions

This chapter contains safety instructions that must be taken into account already in the planning phase.
These instructions guarantee maximum protection of personnel and safe, trouble-free engine operation.
MAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are not all inclusive. If a tool, a procedure, a work method, or an
operating technique that is not specifically recommended by MAN is used, you must be certain that it is
safe for you and for other people. You must also be certain that the product will not be damaged. You must
also be certain that the product will not be made unsafe by the procedures that are used.

2.1 Proper use

The engine is built only for driving ships (marine applications).
Any use other than this is considered to be improper.
MAN does not assume liability for damage resulting from this. The risk lies solely with the operating
company.
Proper use also includes compliance with the operating, maintenance and service work specified by the
manufacturer.
The engine must be used, maintained and repaired only by personnel who are acquainted with it and have
been instructed about the potential dangers.
The manufacturer does not assume any liability for damage to property or personal injury resulting from
unauthorised modifications to the engine.
Manipulation of the injection and control system as may also affect the performance and exhaust gas
behavior of the engine.
This means that compliance with the statutory environmental requirements is no longer assured.
Some engines are only certified as recrational engines or for only 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.

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.

Tip for users

Pay attention to the following information when the engine is being operated:
S The safety instructions in this operator's manual and in the operator's manuals of suppliers.
S The “Technical Specifications” chapter in this operator's manual and those in the operator's manuals
of suppliers.
S Country-specific regulations.

2.2 Contents of the maintenance manual

Each person appointed to work on or with the engine must read and understand the maintenance manual
before doing any work on the engine. This is also applicable if the concerned person has already worked
with such an engine or a similar one or has been trained by MAN.
Thus, knowledge of this manual is mandatory.

2.3 Modifications and conversions to the engine

To avoid dangers and to safeguard optimal performance, neither modifications nor attachments or
conversions should be made on the engine that have not been expressly approved by MAN.
Engine and emission related warrenty do not cover any Tampering, modifications or conversions without a
written permission of MAN, any unauthorized modifications becomes null and void of the exist warrenties.

2.4 Responsibility of the operating company

The operating company is subject to the statutory obligations of industrial safety.
Apart from the instructions on industrial safety in this maintenance manual, the safety, accident prevention
and environmental regulations applicable for the area of application of the engine must be followed.
In doing so, the following is particularly applicable:
S The operating company must be aware of the provisions of industrial safety applicable and in a risk
assessment, it must determine additional dangers that may arise based on the special working
conditions at the place of deployment of the engine. The operating company must implement these in
the form of operational instructions for operating the engine.
S The operating company must check during the entire deployment period of the engine whether the
operating instructions compiled by him meet the current version of rules and regulations and to adapt
the same, if necessary.
S The operating company must clearly control and specify the responsibility for installation, operation,
maintenance, repair and cleaning.
S The operating company must ensure that all employees who work with the engine have read and
understood the maintenance manual.
Moreover, the operating company must train the personnel at regular intervals and inform them about
the risks involved.
S The operating company must provide the protective equipment necessary to the personnel.
S This manual must be kept near the engine and it must be accessible to those working with the engine
whenever required by them.
The operating company is responsible for ensuring that the engine is always operated in technically sound
and operationally safe condition.
Hence, the following is applicable:
S Do maintenance work as they have been described in this maintenance manual completely and at
the intervals specified or have it done by a MAN service workshop / MAN contract partner.
S The operating company must have all safety equipment and devices checked regularly for
completeness and functionality.
S The information in the manual must be followed completely and without any restrictions!

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
14 and the safety notes in all the chapters.
General safety instructions

2.5 Requirements of personnel

2.5.1 Qualifications

WARNING
Risk of injury due to inadequate qualification!
Improper handling may lead to severe personal injuries or damage to property.
Therefore:
S Have special activities done only by persons mentioned in the respective chapters of this manual.
S Ensure that the engine cannot be started by unauthorised persons.
S Ensure orderliness and cleanliness in the working area
S Maintenance work shall be done only by trained specialists.
S Ensure adequate freedom of assembly before beginning the work.

The following qualifications have been mentioned in the manual for various areas of activity;
S Instructed person
has been briefed about the duties assigned and informed about potential hazards in case of improper
conduct.
S Specialist
is one who, based on his technical education, knowledge and experience as well as knowledge of
the relevant provisions, is in a position to discharge the duties assigned to him professionally.
S Electrician
is one who, based on his technical education, knowledge and experience as well as knowledge of
the relevant standards and provisions, is in a position to do work on electrical systems and to identify
potential hazards on his own and to avoid them.
The electrician is trained for the special place of use in which he is engaged and knows the relevant
standards and provisions.
Only those persons are approved as personnel from whom it can be expected that they do their work
reliably. Persons whose reflexes are affected, e.g. by drugs, alcohol or medicines, are not approved.
S When choosing the personnel, observe and follow the regulations concerning age and profession
applicable at the place of deployment.

2.5.2 Unauthorised persons

WARNING
Danger for unauthorised persons!
Unauthorised persons who do not meet the requirements described here, are not aware of the risks
in the working area.
Therefore:
S Keep unauthorised persons away from the working area.
S In case of doubt, talk to the persons and instruct them to leave the working area.
S Interrupt the work as long as unauthorised persons remain in the working area.

2.5.3 Training
The personnel must be briefed and trained regularly. The training must be recorded for better tracking of
the training.

2.6 Personal protective equipment

It is necessary to wear personal protective equipment in order to minimise the risks to health while working.
S Always wear the personal protective equipment necessary for the work being done while doing the work.
S Follow the signboards present in the working area on personal protective equipment.

Industrial protective clothing

is tight-fitting work clothing with low tear strength, with tight-fitting sleeves and without
protruding parts. They are used primarily to protect against injuries, climatic influences
and dirt or contamination.
Do not wear any rings, necklaces or other jewellery on the body while working.

Hard hat
to protect against parts falling down or flying about.

Safety shoes
to protect against heavy parts falling down and skidding on slipper subsurface.

Safety gloves
to protect against the hands from abrasion, getting pricked or deep injuries as well as
from coming into contact with hot or corrosive parts or liquids

Wearing for special work

When doing special work, special protective equipment is necessary. Special reference is made to these in
the various chapters of this manual.

Safety goggles
to protect the eyes from parts flying around and liquid sprays.

Ear protection
to protect against hearing loss caused by noise.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
16 and the safety notes in all the chapters.
General safety instructions

2.7 Special hazards

Residual risks that have been determined are mentioned in the following section.
S Observe and follow the safety instructions listed here and the warnings in other chapters of this manual
in order to mitigate risks to health and to avoid hazardous situations.

Electrical current

DANGER
Mortal danger from electric current!
There is imminent mortal danger if you touch live parts.
Damage to the insulation or individual components may be dangerous to life.
Therefore:
S If the insulation of the power supply gets damaged, shut it down immediately and initiate its repair.
S Have work carried out on the electrical system only by electricians.
S For carrying out any work on the electrical system, de-energise it and check that it is de-energised.
S Shut down the power supply and secure it from being switched on again before completing
maintenance, cleaning or repair work.
S Do not bypass or disable any fuses. Use fuses of the correct ampere rating when replacing fuses.
S Keep moisture away from live parts. This may cause short-circuits.

Moving components

WARNING
Danger of injury from moving components!
Rotating and / or linearly moving components may cause severe injuries.
Therefore:
S During operation, do not reach into moving components or put your hands in moving components.
S Do not open covers during operation.
S Pay attention to the time delay for reaching standstill condition: Before opening the covers ensure that
parts are not moving any longer.
S Wear tight-fitting work clothing in the hazard zone.

Easily inflammable materials - diesel fuel, oils and greases

WARNING
Risk of fire by easily inflammable substances!
Easily inflammable substances, liquids or gases may catch fire and cause serious to fatal injuries.
Therefore:
S Do not smoke within the hazard zone or in the immediate vicinity.
Prohibit working with exposed flames and sources of ignition.
S Keep fire extinguishers handy.
S Report suspicious substances, liquids or gases immediately to the person in charge.
S Discontinue work immediately in case of fire. Leave the hazard zone until the warning is withdrawn.

Coolants - antifreeze and anti-corrosion agent

WARNING
Risk of injury from coolants harmful to health
Coolant contains substances that are harmful to health. Contact with these substances may lead to
severe toxicity, allergies, skin itching or injury to the eyes.
Therefore:
S Observe and follow the safety data sheets of the manufacturer.
S When handling coolants, always wear industrial protective clothing, chemical-resistant safety gloves
and safety goggles.
S Avoid spilling and mist formation.

Hot service products

WARNING
Risk of burn injuries caused by hot service products!
Service products may reach high temperatures during operation and cause burn injuries if you come into
contact with them.
Therefore:
S Before handling service products check whether they are hot. If necessary, allow them to cool down.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
18 and the safety notes in all the chapters.
General safety instructions

Hot surfaces

CAUTION
Risk of burn injuries caused by hot surfaces!
Contact with hot components may cause burn injuries.
Therefore:
S Basically wear industrial protective clothing and safety gloves for doing any work near hot
components.
S Before doing any work, make sure that all components have cooled down to ambient temperature.

Noise

WARNING
Hearing impairment caused by noise!
The noise level occurring in the working area may cause severe hearing impairment.
Therefore:
S Basically wear ear muffs while doing any work.
S Remain in the hazard zone only as long as necessary.

Sharp edges and pointed corners

CAUTION
Risk of injury at edges and corners!
Sharp edges and pointed corners may cause grazes and cuts on the skin.
Therefore:
S Proceed cautiously when working near sharp edges and pointed corners.
S In case of doubt, wear safety gloves.

Dirt or objects lying around

CAUTION
Risk of tripping due to dirt or objects lying around!
Dirt or impurities and objects lying around form sources of skidding or stumbling and may cause
considerable injuries.
Therefore:
S Always keep the working area clean.
S Remove objects that are no longer required.
S Identify stumbling spots with yellow-black marking tape.

Work on the Common Rail system

WARNING
Risk of injury by liquids flowing out!
Fuel lines under high pressure (1800 bar) may cause considerable 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 liquid jets!
In case of defective lines or engine parts, a jet of liquid may leak at high pressure.
The liquid jet may sever limbs and lead to death or most severe injuries.
Therefore:
S Never touch the liquid jet.
S Press the emergency stop button immediately. 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 Have the defective parts repaired.

WARNING
Mortal danger from hydraulic energy sources!
The hydraulic energy sources may cause severe to fatal injuries.
Hydraulically driven parts may move themselves unexpectedly.
In case specific components are damaged, hydraulic fluid may get discharged at high pressure.
Therefore:
S Have work done on the hydraulic system only by trained specialists.
S Before starting any work on the hydraulic system, first switch it off and de-pressurise it. Relieve
the pressure tank completely. Check for de-pressurised condition.
S Do not change pressure settings beyond the maximum values.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
20 and the safety notes in all the chapters.
General safety instructions

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.

Cable harnesses and plug connectors

NOTE
Danger of irreparable damage to plug connectors and to engine control devices.
Danger of contact widening and contact getting damaged.
Damage to property by incorrect handling
Therefore:
S When installing the plug first open the plug lock completely and then insert the plug connector
and lock it.
S Protect plug connectors that have been removed and contacts from entry of dirt or impurities.
S Check cable harnesses and plug connectors only with suitable test device (bushing box).

Electric welding

NOTE
Danger of damage to property by incorrect handling of welding equipment
Component - and electronic damage by electric welding
Therefore:
S Protective device “ANTIZAP SERVICE MONITOR” (MAN item number 80.78010.0002)
Connect the device according to the manual enclosed with it.
S If this device is not available, remove the battery terminals and connect the plus line with the minus
line so that it is permanently electrically conducting.
S Put the battery main switch manually to the driving mode position. For electronic battery main switch,
bypass the “minus” at the contacts to the load relay (jumper cable > 1 mm2) as well as bypass “plus”
at the load contacts of the load relay. In addition, switch in several loads such as: Put the drive starter
switch (ignition) in the driving mode position, warning flashing switch “on”, lighting switch in the
“Driving light on” position and the blower ventilation to “Maximum stage”. The more the number of
loads switched on, the greater is the protection.
After ending the welding work, first switch off all loads, remove all bypass jumpers (restore the original
condition) and then connect the batteries.
S n any case, place the earthing of the welding equipment as close as possible to the welding location.
Do not lay the cable of the welding equipment in parallel to the electrical cables in the vessel.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
22 and the safety notes in all the chapters.
General safety instructions

2.8 Safety equipment

The operating company must retrofit the following safety equipment:

Install emergency stop facility before the engine is put into operation and incorporate it in the safety chain
of the system.
Connect the emergency stop equipment in such a manner that in case of an interruption of the power
supply or restoration of power supply after an interruption, hazardous situations for human beings and
property are ruled out.
The emergency stop facility must always be easily accessible.

WARNING
Mortal danger from non-functional safety equipment and devices!
Safety equipment and devices ensure maximum safety during operation. Even if work processes
become more cumbersome by safety equipment and devices, they should never be disabled. Safety is
ensured only if the safety equipment and devices are intact.
Therefore:
S Prior to starting work, check whether all safety equipment and devices are working and have been
installed correctly.
S Prior to starting the engine, check whether all safety equipment and devices are working and have
been installed correctly.

2.9 Conduct in case of hazards and accidents

Preventive measures
S Always be prepared for accidents or fire!
S Keep first-aid facilities (first-aid box, blankets, etc.) and fire extinguishers ready at hand.
S Check the first-aid equipment and fire extinguishers regularly for completeness and functionality.
S Make persons conversant with accident reporting, first-aid and rescue facilities.
S Perform safety instructions at regular intervals.
S Keep entry routes clear for ambulance vehicles.

In case of an accident: act correctly/

S Remain calm.
S Shut down the engine immediately with the help of the emergency stop button.
S Initiate first-aid measures.
S Raise an alarm with the ambulance and / or fire brigade.
S Rescue persons from the hazard zone.
S Make entry routes clear for ambulance vehicles.
S Inform those in charge.

CAUTION
Accident despite all precautionary measures
If despite all precautionary measures an accident still occurs, e.g. as a result of the points listed below.
Hence, consult a doctor immediately in case of:
S contact with corrosive acid.
S Penetration of fuel in the skin.
S Scalding by hot oil or coolant.
S Antifreeze spatter in the eyes etc.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
24 and the safety notes in all the chapters.
General safety instructions

2.10 Signage
The following icons should be placed near the hazard zone.

WARNING
Risk of injury from illegible icons!
As time goes by, stickers and icons may get dirty or become unrecognisable!
Therefore:
S Always keep all safety, warning and operational notices or instructions in an easily legible condition.
S Clean or replace safety, warning and operating instructions

Electrical voltage
Only electricians should work in working areas marked in this manner.
Unauthorised persons should not enter areas marked in this manner.

Hot surfaces
Hot surfaces, such as engines and hot liquids are not always perceptible. Do not touch
them without safety gloves.

2.11 Environmental protection

CAUTION
Environmental risk from incorrect handling!
Incorrect handling of substances dangerous for the environment, particularly incorrect disposal,
may cause considerable damage to the environment.
Therefore:
S Always observe and follow the instructions mentioned below.
S If substances harmful to the environment reach it inadvertently, adopt suitable measures immediately.
In case of doubt, inform the municipal authorities about the damage.

The following substances harmful to the environment are being used:

Lubricants
Lubricants such as greases and oils contains toxic substances and other substances that are harmful to
the environment. They should not reach the environment. Disposal must be done by a professional
disposal company specialised in disposal.

Diesel fuel
Diesel contains toxic substances that are harmful to the environment. It should not reach the environment.
Disposal must be done by a professional disposal company specialised in disposal.

Coolant
Coolants may contain toxic and other substances harmful to the environment. They should not reach
the environment. Disposal must be done by a professional disposal company specialised in disposal.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
26 and the safety notes in all the chapters.
General Instructions

3 General Instructions

3.1 Purpose of this maintenance instruction

A clean environment is of concern to all of us. MAN has built into your high speed diesel marine engine
efficient emission parts, using genuine MAN parts, in conformance with the Federal Clean Air Act in the
United States. To help keep our air clean, you can do your part by having your engine maintenance
services and all repairs performed in a timely manner.
This Maintenance Manual describes the work on the basic engine as well as on the emission-related
engine components.
The prerequisite for complying with the guaranteed emission values is, among others, complying with
the maintenance specifications given in this manual.

3.2 Scope of warranty for the basic engine (base engine warranty)
The warranty committed by the system suppliers includes defects that occur, which are caused by
improper assembly and installation or defective material with proper and intended use of the engine.
The period of liability begins with the notification of readiness for shipment by MAN to the system supplier
and ends after 24 months or 2000 hours of operation, whichever is earlier.
Defects that may occur as a result of causes described in the following, do not fall under the liability for
material defects:
S Operation with unapproved service products
S Non-compliance with the maintenance intervals
S Modifications to the engine, which have not been expressly approved by MAN in writing
S Manipulations to the control device or any change in the performance parameters
S Disregarding this manual

3.3 US regulations (3.3.1 & 3.3.2 ► US only)

3.3.1 Emission behaviour of the engine for commercial engines

(emission warranty)
MAN assures the system supplier that the engine design, production and equipment are suitable, at the
time of notifying readiness for shipment of the engine, have been carried out to meet the U.S. emission
regulations applicable and are free from defects with respect to material and assembly / installation.
MAN guarantees this characteristic to the system supplier for a period of 60 months or 5000 hours of
operation, whichever is earlier.
Defects, which do not occur as a result of improper assembly / installation on the part of MAN and / or the
use of non-defective materials, are not covered by the warranty commitment. In all other aspects, we take
reference to the terms and conditions of warranty mutually agreed to between MAN and the system
supplier. We refer explicitly once again to carrying out maintenance work described in this manual in time.
The onus for this lies with the owner / operating company.

3.3.2 Emission behaviour of the engine for recreational engines

(emission warranty)
MAN assures the system supplier that the engine design, production and equipment are suitable, at the
time of notifying readiness for shipment of the engine, have been carried out to meet the U.S. emission
regulations applicable and are free from defects with respect to material and assembly and installation.
MAN guarantees this characteristic to the system supplier for a period of 60 months or 1000 hours of
operation, whichever is earlier.
Defects, which do not occur as a result of improper assembly / installation on the part of MAN and / or the
use of non-defective materials, are not covered by the warranty commitment. In all other aspects, we take
reference to the terms and conditions of warranty mutually agreed to between MAN and the system
supplier. We refer explicitly once again to carrying out maintenance work described in this manual in time.
The onus for this lies with the owner / operating company.

3.4 Carrying out maintenance work

Maintenance work must be done by skilled employees or workshops according to the choice of the owner /
operating company under strict compliance with this maintenance manual.
U.S. requirements
No modifications should be made to the engine installation. Any modification represents an infringement of
the applicable U.S. legislation (40 CFR 1068.105(b) (Clean Air Act).
U.S. legislation ► 1042.130(b)
Emissionrelated installation instructions.
Failing to follow these instructions violates federal law (40 CFR 1068.105(b)), subject to fines or other
penalties as described in the Clean Air Act.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
28 and the safety notes in all the chapters.
Maintenance schedule

4 Maintenance work

NOTE
There is the risk of personal injury or damage to property caused by untrained personnel

Therefore:
S Maintenance work should be done only by trained specialists.
S Ensure that the engine cannot be started by unauthorised persons.
S Ensure orderliness and cleanliness in the working area
S Ensure adequate freedom of assembly before beginning the work.

4.1 Maintenance schedule

Your engine is designed to keep maintenance requirements to a minimum. Today’s engines are precision
engineered machines. The engine is designed with efficient emission parts, to help keep our air clean.
However, a certain amount of regular maintenance is still necessary to help assure optimum performance
and reliability. A well-maintained engine conserves fuel, protects against unwanted emissions, and may
prevent a major repair expense at a later date. Follow the service intervals schedule and itemized List of
services or each and make fluid level checks between the scheduled intervals as recommend in your
engine Manual.
The maintenance work must be carried out either after completing a certain number of hours of operation
or latest once a year.

4.2 General information on doing maintenance work

Each maintenance activity is entered in the “Service Record” area of this book (in turn by operating hours
or at annual intervals).
After each service the MAN-authorized workshop will stamp and sign to confirm that the tasks have been
completed correctly in accordance with the maintenance schedule.
It is important to ensure that all entries are duly made in full and are clearly legible.
After each service, a test run is to be performed under full load (max. ship speed) to determine the engine
speed to be achieved. This must not be lower than the nominal (engine) speed (see model plate). This test
is deemed to be evidence of passing the maximum engine load.
Boundary conditions for the engine speed test:
S Ship loaded (Tanks filled and equipment on board)
S No vegetation on the rear section, propeller and shaft system

4.3 Daily maintenance

Daily visual inspection must be done in the course of the on-board routine.

4.4 Service intervals

The maintenance schedule contains the basic maintenance work, M1, M2, M3 and M4 which needs to be
done after the hours of operation or after time intervals, whichever comes first.

4.5 Service products

Tip for users

Information about Service products, refer to the MAN Approved Service Products
https://my.manmn.com/portal/irj/asp

5 Maintenance work according to operating hours for commercial engines

5.1 Light Duty

Maintenance work for Light Duty (LD) 1)

according to opera M1 M2 M3 M4
ting hours
400 x x x
800 x x
1200 x
1600 x x x
2000 x
2400 x x
2800 x x
3200 x x
3600 x
4000 x x x
4400 x
4800 x x
5200 x x x
5600 x x
6000 x
6400 x x x
6800 x
7200 x x
7600 x x
8000 x x
8400 x
8800 x x x
9200 x
9600 x x
10000 x x
1) Scope of the maintenance work, see page 35.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
30 and the safety notes in all the chapters.
Maintenance schedule

5.2 Medium Duty

Maintenance work for Medium Duty (MD) 1)

according to M1 M2 M3 M4
operating hours
500 x x x
1,000 x x
1,500 x
2,000 x x x
2,500 x
3,000 x x
3,500 x x
4,000 x x
4,500 x
5,000 x x x x
5,500 x
6,000 x x
6,500 x x
7,000 x x
7,500 x
8,000 x x x
8,500 x
9,000 x x
9,500 x x
10,000 x x
1) Scope of the maintenance work, see page 35.

5.3 Heavy Duty

Maintenance work for Heavy Duty (HD) 1)
according to M1 M2 M3 M4
operating hours
600 x x x
1,200 x x
1,800 x x
2,400 x x
3,000 x
3,600 x x x
4,200 x
4,800 x x x
5,400 x x
6,000 x x
6,600 x
7,200 x x x
7,800 x
8,400 x x
9,000 x x
9,600 x x
1) Scope of the maintenance work, see page 35.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
32 and the safety notes in all the chapters.
Maintenance schedule

6 Maintenance work according to operating hours for recreational engines

6.1 Light Duty

Maintenance work for Light Duty (LD) 1)

according to opera M1 M2 M3 M4
ting hours
400 x x x
800 x x
1200 x
1600 x x x
2000 x
1) Scope of the maintenance work, see page 35.

7 Maintenance according to time intervals

All Application types 1)

according to time intervals Daily M1 M2 M3 M4

Inspection
Daily x
Annual x x x
After every 5 years x
1) Scope of the maintenance work, see page 35.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
34 and the safety notes in all the chapters.
Maintenance schedule

8 Scope of the maintenance work

Basic maintenance
Daily Daily visual inspection in the course of the on-board routine.
S Engine oil level / gearbox oil level
S Coolant level in the expansion tank
S Function of the instruments
S Engine externally for oil and coolant leakages
S Drain water from the fuel pre-filter
S Abnormal engine noises and smoke development
M1 Check
S Engine externally for oil and coolant leakages
S Coolant level
S Concentration of antifreeze / anti-corrosion agent
S Function of the instruments
S Coolant hoses for leak-tightness
S Coolant lines for leak-tightness
S Condition of the impeller
S Tighten removable connecting elements (screws, hose clamps and pipe connections)
if required
S Condition of the ribbed V-belt
S Visual inspection of the engine cable harness for damage, do not loosen plug connectors
S Elastic mounts of the engine and gearbox
S Alignment of the shaft system
Read out
S Read out the error memory of the MMDS
S Read out and delete the error memory of the EDC
Change
S Engine oil
S Engine filter cartridge
S Fuel filter cartridge1)
S Cartridge of the fuel pre-filter1)
S Air filter
Test drive
S Test drive, speed test with fully loaded ship2)
M2 Check, and if necessary, adjust
S Valve clearance
M3 Carry out diagnostics
S Compression test and rev-up test (TCOM, TRUP)

1) With severe fuel contamination or high water content, the filters must be replaced accordingly.
2) Fully loaded means: Water tank and fuel tank are filled up and ship equipment is complete including
the ship's boat
The maintenance work M1 to M3 mentioned above must be done when the respective hours of operation
have been completed or once a year (see page 34) by a workshop authorised by MAN.

Additional maintenance
M4 Maintain the charge air system and cooling system
S Visual inspection of the turbocharger, see page 68
S Clean the charge air cooler pipe bundle and test the charge air cooler under pressure
if necessary
S Clean the heat exchanger plates
S Changing the coolant
S Replace all hoses for coolant and salt water
S Checking oil separator, see page 45

Tip for users

The maintenance schedule, however, also contains work that are not described in this maintenance
manual starting from page 37 but are given in the repair manual. This work should be done only by
specialists who have been trained particularly for repair.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
36 and the safety notes in all the chapters.
Maintenance work

9 Instructions on maintenance work

9.1 Prerequisite

Tip for users

Before starting the work, read and follow the general safety instructions and the safety instructions given
in this chapter.
Follow the instructions to the letter and proceed cautiously to prevent accidents, personal injury and
material damage.

Personal protective equipment

The following protective equipment must be worn:
S Industrial protective clothing
S Safety shoes
S Safety gloves

9.2 Safety instructions

Personnel
S Only trained specialists should carry out the maintenance work described in the maintenance manual.

Basic rules

WARNING
Risk of injury caused by maintenance not done properly!
Improper maintenance may lead to severe personal injuries or damage to property.
Therefore:
S Ensure that the engine cannot be started by unauthorised persons.
S Have the engine serviced only by trained personnel.
S Carry out all maintenance work in accordance with the information in these maintenance instructions.
S Ensure adequate freedom of assembly before beginning the work.
S Ensure orderliness and cleanliness in the working area! Components or tools lying loose on one
another or lying around are a source of accidents.

WARNING
Risk of injury during maintenance work!
Before carrying out any maintenance work, the engine, unless expressly specified otherwise in the
description, must be put in the maintenance position.
Therefore:
S The engine must be shut down.
S The engine must have cooled down.
S The battery main switch must be switched off and the ignition key must be pulled out.

Tip for users

Expiry of warranty for defects by unapproved service products!
When using unapproved service products the defects liability becomes null and void.
Therefore:
S Use only approved service products (see the publication “Service products ...” for this purpose).

Reference
Information about Service products, refer to the MAN Approved Service Products
https://my.manmn.com/portal/irj/asp

ENVIRONMENTAL NOTE
Liquid coolant
S Treat antifreeze and mixtures of antifreeze and water as hazardous waste. Always observe
the regulations laid down by the relevant local authorities when disposing of used coolants.
Engine oil
S Make absolutely sure that no oil finds its way into the sewage system or is allowed to soak into
the ground or into the water.
− Risk of drinking water contamination!
Collect used oil carefully and send it for used oil recycling.
When handling engine oil observe precautionary measures for health protection.
Filter inserts
S Filter inserts such as, e.g. oil filter, fuel filter are hazardous waste and must be disposed of
professionally. Please follow the regulations issued by the relevant local authority.
Batteries
S Old batteries contain harmful substances. These must be taken back by the seller and disposed of
professionally or given to a collection centre. Never dispose of used batteries in the domestic refuse.
Please also observe and follow national regulations.

ENVIRONMENTAL NOTE
Danger of environmental pollution caused by improper handling of service products
For this reason:
S Comply with the safety regulations.
S If operating supplies harmful to the environment reach it inadvertently, adopt suitable measures
immediately.
S If required, inform the municipal authorities in charge about the damage.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
38 and the safety notes in all the chapters.
Maintenance work

9.3 Instructions on doing maintenance work

The maintenance work listed in the maintenance schedule is described in the following in this maintenance
manual:
S Changing air filter
S Engine oil change
S Changing oil filter element
S Checking Oil separator
S Cleaning the fuel pre-filter with hand pump
S Fuel pre-filter with water separator
- Drain condensed water
- Changing the fuel pre-filter cartridge
S Changing the fuel filter cartridge
S Changing the coolant
S Changing the ribbed V-belt
S Checking / adjusting the valve clearance

9.4 Maintenance work

9.4.1 Engine cleaning

NOTE
Risk of engine damage by hydraulic shock
Functional impairment due to improper cleaning.
Deshalb:
S Do not use a high-pressure cleaner.
S Do not exceed the maximum air pressure at 205 kPa (30 psi).
S Do not exceed the maximum water pressure at 205 kPa (30 psi).
S Minimum distance of the jet nozzle must be at least 30 cm.
S Under no circumstances allow water to pass into the engine.

► Stop the engine and let it cool for 15 minutes

► Check engine for leaks before the washing process and fix them immediately after cleaning.
Dirt tends to collect at leaking points at which service fluids emerge. If this is the case, the engine may
have to be cleaned again after a short time.
► To clean, use bundled tap water jet or steam jet. Do not use a high-pressure cleaner.
► Do not apply water jet directly on shaft seals (behind the vibration damper), tension pulleys, external
sealing joints and hose connections.
► For tightly fitted dirt, use cleaning fluid “Henkel P3-grato 12” (MAN item no. 09.21002-0308). Mix
cleaning fluid in 1:10 ratio with water and spray the engine with it. Then rinse engine with tap water.
► Remove water accumulations on the engine after the washing process (e.g. between the cylinder head
and exhaust pipe)

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
40 and the safety notes in all the chapters.
Maintenance work

9.4.2 Change air filter

Detaching the air filter

► Loosen the hose clamp (2)

► Remove the air filter (1) from the exhaust gas
turbocharger

Attach the air filter

► Push the new air filter (1) on the exhaust gas

turbocharger
► Position the hose clamp (2) and tighten it
Tightening torque . . . . . . . . . . . . . . . . . . . . . 12 Nm

Tip for users

Check the air filter after a few operating hours
for tighteness and if necessary, tighten the hose
clamp.

9.4.3 Engine oil change

WARNING
Risk of injury from hot oil
The engine oil reaches high temperatures during operation and causes scalding if it comes into contact.
For this reason:
S Touch the oil drain plugs only with safety gloves.

NOTE
Risk of material damages due to incorrect tool
Due to the frequency of the impact screwdriver, dirt particles fall out of the filter element.
For this reason:
S Do not release oil filter cover with impact screwdriver.

Tip for users

The oil filter inserts must be replaced at every engine oil change.

Tip for users

To change oil, use a vessel with sufficient capacity, so that no oil overflows.

Special tool

[1] Socket size 36 80.99603-0325

S Removing/installing the oil filter cover

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
42 and the safety notes in all the chapters.
Maintenance work

Draining the engine oil

NOTE
Risk of engine damage due to improper maintenance work

Therefore:
S Before removing the oil filter cover, the entire engine oil must be drained into the oil pan.
S Pay attention to solving paint chips of painted oil filter cover and remove (e.g. compressed air) before
fully opening in order to avoid contamination of the oil circuit.

Drain the engine oil when the engine is at operating temperature.

► Loosen the oil filter cover (1) and unscrew it by

2-3 turns of the thread
► Wait until the engine oil completely drained out
of the oil module into the oil pan

An electrically operated oil extraction and filling

pump is required to pump the oil out of the oil pan,
and this pump can be supplied by MAN.
(1) “Oil in” button
(2) “Oil out” button
(3) Marking for the direction of flow
(4) Hose coupling to connect to the engine
Supply voltage: 24 V

Tip for users

While draining use a container of adequate
capacity!
► Remove the caps (1) and (4)
► Connect the hose coupling (2) to the
connection (1)
► Insert the suction hose of the oil change pump
(3) in to the container
► Connect the power supply of the electric oil
change pump (3) to the connector (4)
► Switch on the oil change pump (3) via the
button “OIL OUT” and pump out the engine oil
without any residue
► Closing the caps (1) and (4)

Changing oil filter element

► Unscrew the oil filter cover (1) with round

sealing ring (3) and oil filter insert (2) and
remove it
► Remove the oil filter insert (2) by turning the oil
filter cover (1) (bayonet lock)
► Remove the round sealing ring (3) from the oil
filter cover (1)
► Clean the oil filter cover (1)
► Thinly apply clean engine oil on the new round
sealing ring (3)
► Fit the new round sealing ring (3) on the oil filter
cover (1)
► Insert the new oil filter insert (2) in the oil filter
cover (1) (bayonet lock)
► Insert the oil filter cover (1) with the oil filter
insert (2) in the oil module and tighten it
Tightening torque . . . . . . . . . . . . . . . . . 40 + 10 Nm

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
44 and the safety notes in all the chapters.
Maintenance work

Checking oil separator

Special tool

[1] Hose clamp pliers for jubilee clips 80.99625-0073

S Removal and installation the jubilee clips

► Undo the jubilee clips (2) using the Hose clamp

pliers for jubilee clips
► Pull off moulded hose (1)
► Unscrew mounting bolts (3)
► Pull oil separator (4) out of oil module
► Remove gasket (5)
► Clean mating faces
Checking oil separator:
-Rotatability (smoothrunning + noiseless)
► Position a new gasket (5)
► Insert the oil separator (4) into the oil module
► Screw in and tighten the mounting bolts (3)
Tightening torque . . . . . . . . . . . . . . . 8,9 ± 2,9 Nm
► Position moulded hose (1) with jubilee clips (2)
► Mount the jubilee clips (2) using the Hose
clamp pliers for jubilee clips

Pouring in engine oil

The oil pan of the engine can be filled up either via the oil filler neck or with the help of the electrical oil
change pump.

ENVIRONMENTAL NOTE
Do not spill any engine oil while filling it. No engine oil should reach into the soil or into the water.

Filling the engine oil via the oil filler neck

NOTE
Risk of engine damage due to incorrect oil
level
Therefore:
S Never fill in more than the quantity of oil
specified.
S Pay attention to the Min/Max marking
on the oil dipstick.
MAX
► Check the engine oil level, see page 48
MIN

Tip for users

Keep the prescribed maximum filling quantity in
the oil pan attached to the engine in a canister.
► Unscrew the cap (1)
► Fill in new engine oil via the oil filler neck
The oil level should lie between the two notches on
the dipstick.
Oil change quantity (with filter).
D2676 LE4.. . . . . . . . . . . . . . . . . . . . . . . . . . 42 litres
► Screw the cap (1) on
► Check the engine oil level, see page 48

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
46 and the safety notes in all the chapters.
Maintenance work

Filling the engine oil with the help of the electric oil change pump

NOTE
Risk of engine damage due to incorrect oil
level
Therefore:
S Never fill in more than the quantity of oil spe
cified.
S Pay attention to the Min/Max marking on the
oil dipstick.
MAX
MIN

Tip for users

Keep the prescribed maximum filling quantity in
the oil pan attached to the engine in a canister.
► Remove the caps (1) and (4)
► Connect the hose coupling (2) to the
connection (1)
► Insert the suction hose of the oil change pump
(3) in to the container
► Connect the power supply of the electric oil
change pump (3) to the connector (4)
► Switch on the oil change pump (3) via the
“OIL IN” button and fill up the engine
Oil change quantity (with filter).
D2676 LE4.. . . . . . . . . . . . . . . . . . . . . . . . . . 42 litres
► Closing the caps (1) and (4)

Check the engine oil level

NOTE
Risk of engine damage due to incorrect oil
level
Therefore:
S Never fill in more than the quantity of oil
specified.
S Pay attention to the Min/Max marking on
the oil dipstick.

► Pull out the oil dipstick (1)

► Wipe off the oil dipstick (1) with a clean lint-free
cloth
► Insert the oil dipstick (1) again until the stop
► Pull out the oil dipstick (1) again and check the Oil dipstick left
oil level
► Insert the oil dipstick (1) again until the stop
► If required, top up the shortfall in the quantity of
oil. do not overfill.

Oil dipstick right

MAX
MIN

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
48 and the safety notes in all the chapters.
Maintenance work

9.4.4 Cleaning the fuel pre-filter with hand pump

WARNING
Risk of fire due to highly flammable substances
Highly inflammable materials, liquids or gases can catch fire and cause serious or fatal injuries.
Therefore:
S Do not smoke in the danger zone or immediate surroundings.
S Naked flames and sources of ignition are strictly prohibited.
S Fire extinguishers must be provided.
S Immediately report any suspicious substances, fluids or gases to the person in charge.
S Stop work immediately in the event of a fire. Leave the danger zone and do not return until it is safe to
do so.

ENVIRONMENTAL NOTE
Fuel getting discharged should reach into the soil or into the water.

Dismantling the fuel pre-filter:

► Close the shut-off valves between the engine
and the tank
► Unscrew the filter housing (1)
► Wash out the filter housing (1) and the
strainer (2) in clean diesel fuel and blow out
using compressed air
► Reassemble with a new gasket
► Screw on and tighten the filter housing (1)
again
Tightening torque . . . . . . . . . . . . . . . . . . 10 + 5 Nm
► Ventilate the fuel system, see page 52

9.4.5 Fuel pre-filter with water separator

ENVIRONMENTAL NOTE
Fuel getting discharged should reach into the soil or into the water.

Draining the condensed water

► Disconnect the electrical connection

► Open the drain plug/sensor (1)
► Allow the condensed water collected to drain
out in a suitable container until only fuel flows
out
► Closing drain plug (1) hand-tightly
► Make the electrical connection

Changing the fuel pre-filter cartridge

► Close the shut-off valves between the engine

and the tank
► Disconnect the electrical connection (2)
► Open the drain plug/sensor (1) and allow the
fuel to drain in a suitable container
► Loosen the filter cartridge (1) with a tension
strap spanner and unscrew it by hand
► Moisten the seal in the new filter cartridge
with fuel
► Screw on the new filter cartridge and tighten it
Tightening torque . . . . . . . . . . . . by hand + 270°
► Closing drain plug/sensor (1) hand-tightly
► Make the electrical connection (2)
► Open the shut-off valves between the engine
and the tank
► Ventilate the fuel system, see page 52
► Check the filter for leaks

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
50 and the safety notes in all the chapters.
Maintenance work

9.4.6 Changing the fuel filter cartridge

ENVIRONMENTAL NOTE
Do not spill any fuel while draining. No fuel should reach into the soil or into the water.

Tip for users

While draining use a container of adequate capacity!

Changing the fuel filter cartridge

► Loosen the filter cartridge (1) with a tension

strap spanner and unscrew it by hand
► Moisten the seal in the new filter cartridge with
fuel
► Screw on the filter cartridge and tighten it
Tightening torque . . . . . . . . . . . . by hand + 270°
► Ventilate the fuel system, see page 52
► Check the filter for leaks

9.4.7 Ventilating the fuel system

ENVIRONMENTAL NOTE
Fuel getting discharged should reach into the soil or into the water.

► Loosen the ventilating screw (1) on the fuel

filter
► Release the plunger (2) of the hand pump
► Operate the plunger (2) of the hand pump until
fuel gets discharged at the ventilation screw (1)
without any bubbles
► Tighten the ventilation screws (1)
Tightening torque . . . . . . . . . . . . . . . . . . 9 ± 2 Nm
► Screw in the plunger (2) of the hand pump
again and tighten it
Tightening torque . . . . . . . . . . . . . . . . . . 3 ± 1 Nm
► Check the fuel system for leak-tightness

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
52 and the safety notes in all the chapters.
Maintenance work

9.4.8 Changing the coolant

Drain the coolant

WARNING
Danger of scalding!
The cooling system is under pressure and the coolant is hot.
Therefore:
S Allow the engine to cool down first
S Touch the coolant drain plugs only with safety gloves.

ENVIRONMENTAL NOTE
Danger of environmental pollution caused by improper handling of service products
Considerable damage is caused to the environment.
For this reason:
S Comply with the safety regulations.
S If operating supplies harmful to the environment reach it inadvertently, adopt suitable measures
immediately.
S If required, inform the municipal authorities in charge about the damage.

Tip for users

While draining use a container of adequate capacity! (Coolant quantity 55 liters)

► Open the cover at the filler neck of the

expansion tank (pressure compensation)
► Unscrew the drain plug (1) (SW17) with the
sealing ring from the oil module
► Remove the cover at the filler neck of the
expansion tank
► Allow the coolant to drain
► Unscrew the drain plug (2) (SW10) and
(3) (SW 17) with the sealing ring
► Allow the coolant to drain completely
► Screw in the drain plug (1) again into the oil
module with a new sealing ring and tighten it
Tightening torque . . . . . . . . . . . . . . . . 90 ± 10 Nm
► Screw in the drain plug (2) and (3) with a new
sealing ring and tighten it
► Fill in / ventilate the cooling system, see 54
► Screw in by hand the cover at the filler neck of
the expansion tank
Covers that have been tightened forcefully can
no longer be opened!

Fill in / ventilate the cooling system

WARNING
Danger of damage to property by high temperature differences
Damage to the engine at operating temperature while topping up cold coolant.
Therefore:
S Do not fill in cold coolant into hot engine.
S Allow the engine to cool down.

NOTE
Damage to the engine by absence of antifreeze and anti-corrosion agent
By not adding antifreeze and anti-corrosion agent properly, the cooling system fails.
Therefore:
S Prepare the coolant in accordance with the publication “Service products for MAN industrial and
marine engines”.

Tip for users

Information about Service products, refer to the MAN Approved Service Products
https://my.manmn.com/portal/irj/asp
The engine cooling system should be filled with a mixture of mains drinking water and antifreeze based on
ethylene glycol or anti-corrosion agent.

While topping up, the cooling system must be

ventilated with the help of the ventilation screw (1)
at the liquid-cooled outer shell of the exhaust gas
turbocharger.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
54 and the safety notes in all the chapters.
Maintenance work

Fill in the cooling system

► Loosen the ventilation screw (1), open the

cover (4)
► Fill up coolant gradually at the filler neck (3) of
the expansion tank, to the upper edge
► Tighten the ventilation screw (1)
► Screw in the cover (4) and tighten by hand
► A commercially available air pump attach to the
valve (5)
► Producing pressure in the expansion tank
► Loosen the ventilation screw (1) until the
coolant gets discharged without any bubbles
► Tighten the ventilation screw (1)
► Open the cover (4)
► Fill up coolant gradually at the filler neck (3) of
the expansion tank, to maximum The engine is installed horizontally
► Screw in the cover (4) and tighten by hand
Covers that have been tightened forcefully can
no longer be opened!
► Allow the engine to run for about 15 minutes at
a speed of 1200 rpm
► Shut the engine down
► The coolant level in the sight glass (4) of the
expansion tank must lie in the middle of the
sight glass
► Before starting the engine the next time (when
the engine is cold), check the coolant level and
top it up if required. To top it up, loosen the
cover (5) cautiously - release the pressure -
then open it cautiously and top up the coolant
► Opening the cooling system while the engine is The engine is installed at an angle to the flywheel side

at operating temperature, see page 56

NOTE
Risk of material damages due to lack of pressure in the cooling system
Engine damage
For this reason:
S Operate cooling system exclusively with functional screw cap.

1. Check the impermeability of the cooling system by overpressure test.

2. Renew leaky screw cap or defective working valves.

Opening the cooling system while the engine is at operating temperature

WARNING
Risk of injury by hot liquids
The coolant reaches high temperatures during operation and causes scalding if it comes into contact.
Therefore:
S Open the cooling system only under exceptional circumstances when the engine is at operating
temperature.
S Loosen the cover cautiously with the safety valve.
S Release the pressure.
S Open the cover cautiously.

If the cooling system is opened while the engine is

at operating temperature, there is a pressure loss
in the cooling system.
During subsequent engine operation, this can
cause the Engine Monitoring and Diagnostic
System (MMDS) to trigger the “Pressure in the
coolant expansion tank” alarm.
To operate the warm engine again after opening
the cap without triggering the alarm, there must be
an initial pressure of 0.5 bar in the cooling system.
To realise this, a pressure valve (1) is mounted on
the coolant expansion tank. A commercially
available air pump can be attached to the valve.
The pressure in the expansion tank must be raised
to 1 bar with this pump.

Tip for users

Currently existing pressure can be read on the
display

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
56 and the safety notes in all the chapters.
Maintenance work

Check the coolant level

Tip for users

In case of overfilling, excess coolant is thrown out via the drain hoses during operation.

Check the coolant level only when the engine has

cooled down.
S In the coolant level sight glass (1), the coolant
level must be visible in the coolant expansion
tank.
S If the coolant level is in “the lower range”, then
coolant must be topped up.

9.4.9 Changing the ribbed V-belt

CAUTION
Risk of injury from crushing
Therefore:
S While turning the engine, do not reach between the ribbed V-belt pulley and the ribbed V-belt.

Check the ribbed V-belt

S Check the ribbed V-belt for tear, oiliness, overheating and wear.
S Replace damaged ribbed V-belts.

Removing V-belt protection

► Unscrew mounting bolts (1)

► Remove carefully downwards the V-belt
protection (2)

Removing the ribbed V-belt

CAUTION
Risk of injury from spring tension
Springing back of the ribbed V-belt tensioner.
Therefore:
S Secure the ribbed V-belt tensioner from
springing back inadvertently by holding it
down.

► Fit the tool on the ribbed V-belt tensioner (2)

► Turn the ribbed V-belt tensioner (2) clockwise
and hold it
► Remove the ribbed V-belt tensioner (1)
► Cautiously release the ribbed V-belt
tensioner (2)

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
58 and the safety notes in all the chapters.
Maintenance work

Check the tension pulley bearing

Check the tension pulley bearing (1) with regard to:

S Zero backlash
S Ease of movement / smooth running
S Lubricant leakage
Replace defective tension pulley.

Check coolant pump

The coolant pump (1) is checked by visual- and

functional inspection.
1. Check coolant pump for:
S Coolant leaks at the coolant pump, especially at
coolant pump bearing
2. Check coolant pump bearing (2) for:
S Zero backlash
S Ease of movements / smooth running
Replace defective coolant pump.

Installing the ribbed V-belt

CAUTION
Risk of injury from spring tension
Springing back of the ribbed V-belt tensioner.
Therefore:
S Secure the ribbed V-belt tensioner from
springing back inadvertently by holding it
down.

► Turn the ribbed V-belt tensioner (2) clockwise

and hold it
► Put the new ribbed V-belt (1) in place
► Cautiously release the ribbed V-belt
tensioner (2)
► Remove the tool from the ribbed V-belt
tensioner (2)

Installing V-belt protection

► Attach the V-belt protection (2)

► Screw in and tighten mounting bolts (1)

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
60 and the safety notes in all the chapters.
Maintenance work

9.4.10 Checking the valve clearance and adjusting it

NOTE
Incorrectly adjusted valves
Damage to the engine by incorrectly adjusted valves
Therefore:
S Adjust the valves only when the engine is cold

Technical data
Mounting bolts of the cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Rocker arm lock nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Valve clearance for inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm
Valve clearance for outlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm

Special tools

[1] Engine cranking unit 80.99626-6008

S Crank the engine in conjunction with:
S Gear ratchet

[2] Gear ratchet 80.99627-0001

S Crank the engine in conjunction with:
S Engine cranking unit

[3] Feeler gauge 08.75310-3309

S Checking the valve clearance and adjusting it:

[4] Valve adjustment spanner SW 14 80.99603-6031

S Checking the valve clearance and adjusting it

[5] Torque wrench 08.06450-0006

S Checking the valve clearance and adjusting it

[6] Ratchet 08.06410-9072

S Checking the valve clearance and adjusting it

[7] Handle 08.06460-0003

S Checking the valve clearance and adjusting it

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
62 and the safety notes in all the chapters.
Maintenance work

Dismantle the cylinder head cover

Tip for users

The mounting bolts can only be removed from
the cylinder head cover with damping elements
and spacer sleeves

► Unscrew mounting bolts (4), (5) and (6)

► Remove the cylinder head cover (3) with gasket
(2) from the cylinder head (1)
► Clean cylinder head cover (3) and gasket (2)
► Check gasket (2) for damage. If necessary,
remove from cylinder head cover (3) and
replace
► Set aside cylinder head cover (3) on a clean
surface with the gasket facing downwards

Tip for users

If this is not done, engine oil can penetrate the
gasket profile. This oil is pressed out when the
cylinder head cover is tightened, making it ap
pear like a leakage.

Attach the engine cranking unit

► Disassemble the cover from the flywheel

housing
► Attach the engine cranking unit (1) [1] to the
flywheel housing

Turn the engine to the adjustment position

► Turn engine in engine´s running direction

(arrow) using engine cranking device [1] and
gear ratchet [2] until 1st cylinder is at TDC
mark

Tip for users

Observe TDC mark on flywheel.
6th cylinder rocker arms are in overlap
Black marked valves can be adjusted
► Continue turning engine a further 360° until 6th
cylinder is at ignition TDC
1th cylinder rocker arms are in overlap
White marked valves can be adjusted

Checking the intake valve clearance

► Insert the feeler gauge [3] (3) with the 0.5 mm

feeler (2) between the ball cup (1) and the valve
bridge (4)
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . 0,5 mm
The valve clearance must be adjusted if it is not
0.50 mm.

Adjusting the intake valve clearance

► Undo the lock nut (2) and adjusting screw (1)

► Insert the feeler gauge [3] (5) with the 0.5 mm
feeler (4) between the ball cup (3) and the valve
bridge (6)
► Screw in the adjustment screw (1) until the
feeler gauge [3] (5) with 0.5 mm feeler (4) can
be moved with low resistance between the ball
cup (3) and the valve bridge (6)
► Hold the adjustment screw (1) tight with the
valve adjustment spanner SW 14 [4], Ratchet
[6] and Handle [7]
► Tighten the lock nut (2) with a torque wrench [5]
Tightening torque . . . . . . . . . . . . . . . . . . . . . 45 Nm
►. Check setting again; repeat adjustment process
if necessary

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
64 and the safety notes in all the chapters.
Maintenance work

Checking the exhaust valve clearance

► Insert the feeler gauge [3] (3) with the 0.8 mm

feeler (2) between the ball cup (1) and the valve
bridge (4)
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . 0,8 mm
The valve clearance must be adjusted if it is not
0.80 mm.

Adjusting the exhaust valve clearance

► Undo the lock nut (2) and adjusting screw (1)

► Insert the feeler gauge [3] (5) with the 0.8 mm
feeler (4) between the ball cup (3) and the valve
bridge (6)
► Screw in the adjustment screw (1) until the
feeler gauge [3] (5) with 0.8 mm feeler (4) can
be moved with low resistance between the ball
cup (3) and the valve bridge (6)
► Hold the adjustment screw (1) tight with the
valve adjustment spanner SW 14 [4], Ratchet
[6] and Handle [7]
► Tighten the lock nut (2) with a torque wrench [5]
Tightening torque . . . . . . . . . . . . . . . . . . . . . 45 Nm
► Check setting again; repeat adjustment process
if necessary

Removing engine cranking device

► Dismantle the engine cranking unit (1) at the

flywheel housing
► Attach the cover from the flywheel housing

Clinder head cover installation note

Tip for users

A = Intake end
B = Exhaust end
► Installation position of mounting bolts with
bushes (1)
► Installation position of mounting bolts with
springs (2)
► Installation position of mounting bolts with with
damping elements (3)

Tightening sequence for cylinder head cover

A = Intake end
B = Exhaust end
Stick to the illustrated mounting bolt tightening
sequence 1 to 18 in the following work step

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
66 and the safety notes in all the chapters.
Maintenance work

Mounting the cylinder head cover

► Check the gasket (2), replace if necessary

► Place the cylinder head cover (3) with gasket
(2) on the cylinder head (1)

Tip for users

Springs screws are used only on the cold side
(ECU side).
► Check the correct installation position of the
mounting bolts (4), (5) and (6)
► Screw in the mounting bolts (4), (5) and (6)
► Tighten the mounting bolts (4), (5) and (6) in
the tightening sequence
Tightening torque . . . . . . . . . . . . . . . . . . . . . 10 Nm

9.5 Checking the exhaust gas turbocharger

Visual inspection of the turbocharger with respect to
- Traces of streaks between the impeller wheel and impeller housing
- Deformed vanes, damaged inlet edges by the impact of foreign bodies
- Oil leakage in the impeller and bearing housing
- Strong oil deposit at the impeller ► checking separator (Oil module), page 45
Checking the turbocharger with respect to
- Ease of movement of the rotor shaft
- Checking the oil pressure and oil return flow lines for leak-tightness, tight fit and damage

9.6 Checking the cable connection and connector for tight fit
Check all plug connectors and cable connections of the engine cable harness for tight fit.
Do not open the plug connectors while doing so.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
68 and the safety notes in all the chapters.
Troubleshooting and diagnostics

10 Troubleshooting and diagnostics with MAN-cats®

10.1 Using MAN-cats® in maintenance

MAN-cats® is a testing and diagnostic system developed by MAN. This system offers the option to check
all major engine functions using a service computer and thus to detect defective parts and errors.
MAN cats® is thus a tool that is used in addition to the basic maintenance of the engine. The basic
maintenance comprises visual- and functional checks in addition to changing operating supplies and filters.
With MAN cats®, complete systems of the engine can be analytically tested and consequential damages,
or even a total failure of the engine can thus be prevented.

10.2 Instructions on use of MAN cats®

The formal use of MAN cats® is easy to learn after a short introduction. In carrying out the individual test
steps, the user is guided by the software on the service computer.
Moreover, an extensive documentation is available to the user if required.
MAN cats® is a tool for testing of engine systems. However, it requires expertise and experience to
interpret the information provided by MAN cats®. A thorough diagnosis can therefore only be performed by
qualified technical personnel.

Tip for users

MAN cats® may only be used by trained technical personnel.

10.3 Performing diagnosis

For the MAN cats® user, a detailed service literature is provided by MAN. Therefore, only an overview of
the MAN cats® test steps is listed in this manual.
This is the recommended sequence of test steps:
1. Read out diagnostic memory
2. Monitoring / actuator test / compression test / rev-up test
3. Clear the diagnostic memory.

Proceed when reading out the diagnostic memory as follows:

1. Read out diagnostic memory, eliminate causes of pending faults. Consult MAN service if required.
2. If the causes of the fault are eliminated, read out the diagnostic memory again. The error may now only
be shown as “saved”.
3. Clear the diagnostic memory.

Read the maintenance manual carefully before starting any work!

This is particularly valid for the chapter General safety instructions
and the safety notes in all the chapters. 69
Troubleshooting and diagnostics

10.3.1 Compression test

The compression test is used to determine the compression deviation of the individual cylinders. For this
purpose, the engine is turned over by the starter motor. The control unit suppresses injection (engine does
not start) and, for each cylinder, measures how severely the starter motor was braked during the
compression cycle.
The starter motor must be actuated via the ignition lock until the control unit has measured the speeds at
bottom dead center (BDC) and shortly before top dead center (TDC) for all cylinders. The speed briefly
reaches its minimum at the TDC of each cylinder. This is the point of maximum compression. This means
that severe braking – i.e. a low speed before TDC – indicates relatively good compression.

Procedure and requirements:

- Battery 100 % charged
- Engine at operating temperature > 75 ° C
- Warm up the vehicle, do not run it warm
- Quickly follow the instructions given by MAN-cats® (otherwise no analysis)
- It is essential that the ignition is turned off following completion of the compression test

Results for an intact engine (example)

Cylinder Lower speed (rpm) Upper speed (rpm) Difference (rpm)

1 209 243 34
5 208 243 34
3 208 241 33
6 208 242 34
2 207 242 35
4 209 241 32

The result takes the form of two speeds for each cylinder:
Lower speed: this is the lower of the two speeds measured during the compression cycle (approx. 8°
upstream to 8° downstream of TDC).
Upper speed: this is the higher of the two speeds measured far before TDC (approx. 70° before TDC).

Assessment of the analysis:

- Classification of defects for larger differences (valve damage, piston ring damage, etc.).
If a cylinder is damaged, the values for the other cylinders can also vary significantly.
- The result depends on the number and type of power take-offs.
- The result depends on the engine temperature.
The test should be performed three times in a row due to scattering.

Read the maintenance manual carefully before starting any work!

This is particularly valid for the chapter General safety instructions
70 and the safety notes in all the chapters.
Troubleshooting and diagnostics

10.3.2 Rev-up test

The rev-up test can only be analyzed in conjunction with the compression test. The rev-up test is used to
check the cylinders for even function. For this purpose, individual cylinders are switched off consecutively
and the engine is accelerated from idling speed. The engine speed acceleration is then calculated. Faulty
injections or defective cylinders can be determined by the differences between the deactivated cylinders.
To be precise, in order to determine whether all cylinders offer the same performance, the rev-up test
measures what speed the engine can reach in a specific time with a defined injection quantity. During the
rev-up test, seven consecutive rev-ups are performed: During the first rev-up, all injectors are activated and
the achieved speed determined. As of the second rev-up, the engine is again accelerated, but the injectors
are shut off one after the other in firing order. If the engine now reaches almost the same speed as during
the first rev-up, despite the injector being switched off, this cylinder is not working well during engine
operation and has a lower performance.

Procedure and requirements:

- Engine at operating temperature > 75 °C.
- Warm up machine, do not run warm.
- Always conduct the rev-up test at least three times. It is important that no other loads or power
take-offs are switched on. Alright are auxiliariy consumers (electricity, alternator or hydraulic) which
generate the constant load. During the rev-up test, do not switch.
- At the end of the rev-up test, always switch off the ignition, otherwise the smooth running control will
not be activated.

Example for a test result is given below, where cylinder 3 shows abnormalities:

Cylinder Speed acceleration (rpm/sec) Difference cylinder not switched off

0 704 0
1 550 154
5 540 164
3 630 74
6 566 138
2 535 169
4 542 164

If the engine now reaches almost the same speed as during the first rev-up despite Injector 3 being
switched off, this cylinder is not working well during engine operation. This does not, however, mean that
this cylinder's injector is defective! It only indicates that the cylinder concerned is not performing as well.
This means that the engine mechanics must also be checked: Valve clearance, compression etc. The
rev-up test can thus only be analyzed in conjunction with the compression test. The rev-up test only
compares the cylinders with each other. The result also has to match the adjustment quantities.

Tip for users

If the lines of a current path are disconnected, only the defective injector is switched off, i.e. the rev-up
test can be carried out and indicates the current path affected. If there is a short circuit in a current path
to an injector, all injectors in the affected bank are switched off, i.e. a 6-cylinder in-line engine then only
runs on three cylinders. The rev-up test is aborted with an SPN message because the engine is then
only running on two cylinders

Read the maintenance manual carefully before starting any work!

This is particularly valid for the chapter General safety instructions
and the safety notes in all the chapters. 71
Troubleshooting and diagnostics

10.3.3 High-pressure test

The high-pressure test checks the flow rate of the high pressure pump and the impermeability of the
injection system on the high-pressure side.
In the test, the rail pressure is regulated four times to 1600 bar and back to 600 (once at 800 rpm and three
times at 700 rpm). In this process, the pressure build-up time and the pressure reduction time is measured
and output as the result.
These times allow conclusions to be made regarding the system's integrity and/or malfunctions of certain
components.

Procedure and requirements:

- Engine at operating temperature > 75 ° C.
- Warm up machine, do not run warm
- Gearbox in neutral
- Start engine > idle speed to max. 750 rpm permitted

As limit, the following values apply:

- Depressurization time: minimum XXX ms, maximum XXXX ms
(Measured values for intact system: XXXX-XXXX ms).

Depressurization time of less than XXX ms:

- Leakage on the load side (injector, pressure pipe sockets, pressure-limiting valve). If the result is
less than XXX ms, we recommend performing the test again with the line on the pressure-limiting
valve open to isolate the fault(s).
- Any detection of one or more loose pressure pipe socket is heavily dependent on the temperature of
the engine.
- The pressure-limiting valve must not leak during testing!

Depressurization time greater than XXXX ms:

- Jamming of the M-Prop (ZME), clogged zero-feed throttle high pressure pump, clogged return line.
- Too high pressure in fuel return to the tank.
- Unequal pressurization times (at the same depressurization times) also point to jamming of ZME.
- However, if there are error entries in the diagnostic memory of the EDC error messages, but the
depressurization times are OK, the error is to be found in the high-pressure pump (process of
elimination)!

Tip for users

The test can be carried out from a coolant temperature of at least 40 °C. Below that, the test is aborted.

Read the maintenance manual carefully before starting any work!

This is particularly valid for the chapter General safety instructions
72 and the safety notes in all the chapters.
Troubleshooting and diagnostics

10.3.4 Meaning of symbols when reading out the diagnostic memory

No fault

Fault stored

Intermittent fault

Fault active and has been stored

Fault not specified

Too high

Too low

Implausible

No signal present

Short to GND

Short-circuit to UB

Short circuit

Faulty signal

Device fault

Open load

Not defined

Read the maintenance manual carefully before starting any work!

This is particularly valid for the chapter General safety instructions
and the safety notes in all the chapters. 73
Troubleshooting and diagnostics

Read the maintenance manual carefully before starting any work!

This is particularly valid for the chapter General safety instructions
74 and the safety notes in all the chapters.
Taking out of operation and returning to operation

11 Taking out of operation and returning to operation

11.1 Prerequisite

Tip for users

Personal protective equipment

The following protective equipment must be worn:
S Industrial protective clothing
S Safety shoes
S Safety gloves
S Safety goggle

11.2 Safety instructions

Personnel
S Only trained specialists should take an engine out of operation and return it back to operation.

Basic rules

WARNING
There is the risk of injury to personnel caused by untrained personnel

For this reason:

S Ensure that the engine cannot be started by unauthorized persons.
S Have the engine serviced only by trained personnel.
S Carry out all work steps in accordance with the information in this maintenance manual.
S Ensure adequate freedom of assembly before beginning the work.
S Ensure orderliness and cleanliness in the working area! Components or tools lying loose on one
another or lying around are a source of accidents.

12 Taking the engine out of operation temporarily

Ships are deployed several times depending on the season.
During a longer period of shut-down, the engine is exposed to the corrosive influence of the environment.
In particular, the moisture contained in the ambient air as well as the formation of condensed water when
the dew point is undershot lead to corrosion damage on cylinder liners, piston rings and valves.

NOTE
Corrosion damage to the cylinder liners, piston rings and valves after the engine has been taken
out of operation for longer periods.
Therefore:
S Observe and follow the measures for anti-corrosion.

12.1 Taking the engine out of operation for up to 3 months

Even simple measures prior to temporary shut-down provide effective protection against corrosion:
S Clean the engine outside thoroughly with compressed air. Dry the engine surface.
S Fill the fuel tank with approved diesel.
S Establish the concentration of the antifreeze in the coolant and the prescribed mixing ratio, refer to
the publication “Service products for MAN industrial and marine engines”.
S Close all engine openings (for intake air and exhaust gas) so that no air exchange can take place with
the inside of the engine.
S Drain water from the sea water pump/circuit.

Reference
Information about Service products, refer to the MAN Approved Service Products
https://my.manmn.com/portal/irj/asp

12.1.1 Taking the engine out of operation for between 3 to 6 months

If the engine is shut down for more than 3 months, engine preserving agent is necessary in addition to
the measures mentioned in 12.1.

12.1.2 Preserving agent for the fuel system

The fuel system and the combustion chambers of the engine are preserved by operation with the
anti-corrosion fuel. Anti-corrosion fuel is a mixture of conventional diesel and 2 % vol. For corrosion
protection agents, see MAN works standard M 3069.
The fuel system must be preserved as follows:
S Keep anti-corrosion fuel ready in a container.
S Connect the fuel system of the engine to this container.
S The engine is run for 5 minutes at full load (with nominal rpm) and for 1 minute at 1100 rpm and part
load, so that the entire fuel system is filled with corrosion-inhibiting fuel.
S Shut down the engine.
S Close the openings for intake air and exhaust gas air-tight until the engine is still hot.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
76 and the safety notes in all the chapters.
Taking out of operation and returning to operation

12.1.3 Preserving the intake and exhaust gas system

S Spray corrosion protection oil (see MAN works standard M 3249, Temporary corrosion protection ,
MAN part number 09.11002-0025) into the air intake manifold and exhaust pipe.
S Close the openings for intake air and exhaust gas air-tight until the engine is still hot.

12.2 Restarting engines that have been shut down

Proper and careful restarting of new engines or those that have already been run has a great impact on
their operational safety and residual service life. Basically, you must endeavour to preserve engines at the
time of shutting them down.
If the engine had not been preserved before being shut down, there is the danger of cylinder liners, piston
rings and valves getting corroded, especially if the intake air and exhaust gas openings have not been
closed and the engine has been stored outdoors. Foreign substances that have penetrated, rainwater
and similar sometimes require complete disassembly of the engine.
This is why you need to differentiate in the procedure for start-up between engines that have been
preserved and those that have not been preserved:

12.2.1 Putting preserved engines into operation according to the M 3069 MAN
works standard
S Remove external preservation and do not use a high-pressure cleaner under any circumstances.
S Remove the cover from the intake and exhaust gas outlet.
S Check the cooling system, fill up antifreeze according to the service products list (see the “Service
products ...” publication for this purpose), check the concentration and correct it if required.
S Check the engine oil level, and top up with fresh engine oil if required.
S Fill up fuel and ventilate the system.
Check the function of the monitoring and emergency shut-down equipment.
S Check elastic connecting elements such as V-belt, coolant and charge air hoses for their condition,
and check for proper assembly or correct tensioning.
S Crank the engine with the starter without filling it up until oil pressure builds up, and operate the stater
for maximum 5 seconds while doing so.
S Allow filling and start the engine.
S Check the engine for potential leakage points, check for abnormal noise development and observe
the oil pressure and temperatures. Start up the engine by increasing the load in steps.
S After maximum 25 hours of operation drain oil with corrosion protection from the engine, replace the oil
filter, and fill up fresh approved engine oil.

12.2.2 Starting up non-preserved engines

In addition to the work steps for a preserved engine, putting unpreserved engines into operation requires
the following additional work depending on potential damage caused during standstill:
S Perform endoscopy on the combustion chambers and disassemble and install injectors for this purpose.
Check the valves for free movement, check the valve clearance.
Replace damaged / corroded parts.
S Drain used engine oil from the engine and replace the oil filter, and fill up fresh approved engine oil.
S Check the cooling system for corrosion, check the coolant for its concentration and condition, and
replace it in case of doubt. First clean the coolant chambers and, if necessary, disassemble and install
the coolant pump and thermostats, thermostat inserts, and test the cooling system under pressure.
S Check the clean air system, air filter and exhaust gas turbocharger for dirt or impurities, and clean or
repair them if required.
S Clean the fuel system and drain the old fuel if necessary. Check the filter, and clean or replace it,
if necessary.

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
78 and the safety notes in all the chapters.
Maintenance record - Commercial engines

Maintenance record
Commercial engines

Regarding the engine oil / viscosity grade

Max. engine speed at full load (Starboard engine)

Max. engine speed at full load (Middle engine)

Max. engine speed at full load (Port engine)

Next maintenance (Date and / or operating hours)

Stamp, date and signature

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
92 and the safety notes in all the chapters.
Maintenance record - Commercial engines

Application type Light Duty Medium Duty Heavy Duty

according to operating hours 10000

Place

Carried out at operating hours

Invoice number

Regarding the engine oil / viscosity grade

Max. engine speed at full load (Starboard engine)

Max. engine speed at full load (Middle engine)

Max. engine speed at full load (Port engine)

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
98 and the safety notes in all the chapters.
Maintenance record - Commercial engines

9 Years
Place

Carried out at operating hours

Date

Stamp, signature

10 Years
Place

Carried out at operating hours

Date

Stamp, signature

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
100 and the safety notes in all the chapters.
Maintenance record - Recreational engines

Maintenance record
Recreational engines

Stamp, date and signature

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
104 and the safety notes in all the chapters.
Maintenance record - Recreational engines

2000
Place

Carried out at operating hours

Invoice number

Regarding the engine oil / viscosity grade

Max. engine speed at full load (Starboard engine)

Max. engine speed at full load (Middle engine)

Max. engine speed at full load (Port engine)

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
110 and the safety notes in all the chapters.
Maintenance record - Recreational engines

9 Years
Place

Carried out at operating hours

Date

Stamp, signature

10 Years
Place

Carried out at operating hours

Date

Stamp, signature

Before starting any work, make sure to carefully read these instructions!
This is particularly valid for the chapter General safety instructions
112 and the safety notes in all the chapters.

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