Operatio Instructions D2676LE4xx

Operating Instruction
MAN Marine Diesel Engines

IMO Tier III / EU Stage V / US Tier 3
D2676 LE4XX
51.99587-5041 “Translation of the original instruction”

Version 01
Imprint
Subject to amendment.
All information, texts, drawings, figures and other content are protected by copyright law and subject to
industrial property rights. Any improper use shall be liable to prosecution.
It is not permitted to change the contents of this document. The same applies to changes to the context of
individual chapters and/or the whole document. MAN Truck & Bus assumes no liability for any damages
arising from non-compliance with the above provisions.
Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without
the prior written approval of MAN Truck & Bus. All rights deriving from copyright law are expressly reserved
by MAN.
MAN Truck & Bus SE

Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
E-Mail: Engine-Documentation@man.eu
Internet: www.engines.man.eu
Technical status as on: 02/2020

51.99587-5041
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 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information about these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.1 Supplementary publications to these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.2 Other publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Content of these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Unauthorized persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5.3 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.9 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10 Conduct in the event of hazards and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.11 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.12 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Explanation of engine no. (Engine identification number) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Explanation of the model name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Emission label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.1 Duplicate emission label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Body and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.1 Application areas of the engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Engine body and engine equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4.1 View from the front left - classified engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4.2 View from behind right - classified engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4.3 View from the front left - non classified engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4.4 View from behind right - non classified engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
and the safety notes in all the chapters. 3
Table of contents
5 Transport, packing and storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.3 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3.1 Interfaces between the engine and system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3.2 Installation drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.3.3 Bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4 Completing the engine and assembling the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.1 Accessibility to the E-box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.2 Attachment of an alternator to the flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.3 Check the axial clearance of the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5 Installing the drive system in the ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.5.1 Install the elastic engine and gearbox mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6 Connecting the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.6.1 Connect the sea water lines for engine cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.6.2 Additonal cooling water supply of other components . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.7 Connect the fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.7.1 Connect the fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.7.2 Installing fuel pre-filter and hand pump - classified engines . . . . . . . . . . . . . . . . . . . 55
6.7.3 Installing fuel pre-filter and hand pump - non classified engines . . . . . . . . . . . . . . . . 58
6.8 Exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.8.1 Exhaust gas outlet at the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.8.2 Connecting the exhaust gas system to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.9 Connect the cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.10 Power take-off/Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.10.1 Hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.11 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.11.1Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.11.2 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.11.3 Cover for the vibration damper (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.12 Connector plugs on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.13 Values of torque for screw connections according to the M 3059 works standard . . . . . . 69
6.14 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.14.1 Filling with AdBlue®/DEF/AUS32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.14.2 Filling with diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.14.3 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.14.4 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.14.5 Leakage check of the entire cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table of contents
7 Control and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.1 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.3 Preparations prior to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.3.1 Check the fuel supply and top it up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.3.2 Checking DEF/AdBlue®/AUS32 and topping it up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.3.3 Check the coolant level and top it up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.3.4 Check the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.3.5 Topping up the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.3.6 Drain the separated water of the fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.3.7 Changing over the fuel pre-filter/fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.3.8 Selector lever - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.3.9 Daily inspection before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.4 Operate the engine in driving mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.4.1 Operating ranges for marine engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

8.1 Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.2 Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10 Decommissioning and recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.3 Taking the engine out of operation temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.3.1 Taking the engine out of operation for up to 3 months . . . . . . . . . . . . . . . . . . . . . . . 90
10.3.2 Taking the engine out of operation for 3 to 6 months . . . . . . . . . . . . . . . . . . . . . . . . 90
10.4 Restarting engines that have been shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.4.1 Putting preserved engines into operation according to the M 3069 MAN factory
standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.4.2 Commissioning of unpreserved engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.5 Decommissioning and recommissioning of the DEF/AdBlue®/AUS32 system . . . . . . . . . 92
11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.1 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.2 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.3 Requirements of the installation site and space requirement . . . . . . . . . . . . . . . . . . . . . . . . 94
11.4 Engine specifications - Light-duty operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.4.1 D2676 LE426 / LE456 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.5 Engine specifications - Medium-duty operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11.5.1 D2676 LE428 / LE438 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11.6 Engine specifications - Heavy-duty operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.6.1 D2676 LE477 / LE487 / LE497 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Table of contents
12 Installation drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
13 Indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
13.2 Technical terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
13.3 Keyword Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Preface
1 Preface
These instructions apply to the following engines:
Engine types Output in kW Nominal speed Emission level Aftertreatment system

Yes No
Light duty
D2676 LE426* 588 2300 IMO Tier II / US Tier 3 x
D2676 LE456* 625 2300 IMO Tier II / US Tier 3 x
Medium duty
D2676 LE428 441 2100 IMO Tier III x
Heavy duty
D2676 LE487 290 1800 IMO Tier III / EU Stage V x
* not a commercially approved engine
1.1 Information about these instructions

These instructions contains information on assembly, operation and maintenance of the engine.
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 the reliable use of your engine.
Use only genuine MAN spare parts and accessories or those that have been approved by MAN.
Only genuine spare parts that we have approved are checked by us and therefore possess proper
requirements for engine use.
MAN places great importance on improving environmental protection.
This begins as early as the design and development stage of our engines. We take great care to ensure
that no materials which are harmful to the environment are used and that, for example, emission values
meet the highest statutory requirements.
Efficient operation contributes to the conservation of our resources and our environment.
Read these instructions carefully before starting any work!

This is particularly applicable to the chapter "General Safety Instructions"
and the respective safety instructions in the chapters. 7
Preface
1.1.1 Supplementary publications to these instructions

These operating instructions include the publications
- Service products for MAN industrial and marine diesel engines
- Maintenance Manual
All documents are parts of the product and must be kept near the engine so that they can be accessed by
the personnel whenever required.
Read these instructions carefully before starting any work! This is particularly applicable to the chapter
"General Safety Instructions" and the respective safety instructions in the chapters.
Ignoring these instructions and any Operating Instructions of suppliers enclosed leads to warranty claims
becoming null and void.
1.1.2 Other publications

The following instructions are available as supplements to these instructions:
- Spare parts catalog (included in the scope of supply)
- Installation Instructions
- Operating Instructions „MAN Intelligent Marine Safeguard System“ (iSea / iSea Class)
In addition, for engines with aftertreatment system
- (Emission-related) Installation instructions - Modular aftertreatment system, marine
- Maintenance Manual - Modular aftertreatment system, marine

8 and the respective safety instructions in the chapters.
Preface
1.2 Explanation of icons
Warnings
Warnings in these instructions are identified by icons. The information has been introduced with
signal words that express the extent of risk or danger.
Follow the instructions in all cases and proceed with care in order to prevent accidents, personal injury and
material damage.
DANGER
Describes an immediate hazardous situation that will lead to severe or fatal injuries if it is not avoided.
WARNING
Describes a potentially hazardous situation that may lead to severe or fatal injuries if it is not avoided.
CAUTION
Describes a potentially hazardous situation that may lead to minor or moderate injuries if it is not
avoided.
NOTICE
Describes a potentially hazardous 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 WARNING
Tips on conduct for environmental protection.
General notices
• This sign indicates a list in the first level.
► This symbol indicates an action or series of actions.
[1] This symbol indicates the position of a special tool after the list in the chapter
(1) This symbol indicates the position of a graphic in the text.
1 This symbol displays the position of a graphic in the text.

Preface
1.3 Limitation on liability

All information and notices in these instructions 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 these instructions
S Improper or unintended use
S Use of untrained personnel
S Unauthorized conversions
S Technical modifications
S Use of unapproved spare parts and service products
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 agreed upon in the supply contract and the general terms and conditions of MAN, and the
statutory regulations valid at the time of concluding the contract shall be applicable.
1.4 Copyright protection

Treat the instructions as confidential. It is meant only for those working with the engine.
Handing over the maintenance instructions to third parties without express written consent from MAN is
forbidden.
Tip for users

All information, texts, drawings, figures and other content are protected by copyright law and subject to
industrial property rights.
Any improper use shall be liable to prosecution.
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 applicable European and national regulations has been declared by
the respective suppliers of the components.

Preface
1.6 Spare parts

Maintenance, repair or replacement of spare parts can be performed by any authorized service and repair
branch without impacting the emissions parts while doing so.
As a prerequisite, the repairs must be carried out in accordance with the manufacturer specifications and
the spare parts must be at least equivalent to genuine MAN parts in terms of emission behavior and
durability. However, warranty repairs and replacements must be carried out by an authorized MAN dealer.
We recommend using exclusively original MAN spare parts and accessories or parts approved by MAN.
Only MAN approved original spare parts are checked by us and thus possess the suitable prerequisites for
using the engine.
In the event that genuine MAN spare parts are not used, the proprietors should ensure that such parts are
guaranteed by the manufacturer and are at least equivalent to genuine MAN parts in terms of emission
behavior and durability. Despite ongoing market observation, we cannot assess this for other products nor
certify the same.
WARNING
Risk of injury from incorrect spare parts
Use of incorrect or defective spare parts may lead to damage, malfunctions or total failure, affect
emission behavior and may also affect safety.
For this reason:
S Suggestion: Use only genuine MAN spare parts
Tip for users

Please mention the engine type, engine number and the order number with all communication.
Order spare parts from an authorized dealer or directly from MAN.

Address, see page LEERER MERKER.
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 sorted according to the material properties
S Handling service products, see page 25

Preface
1.8 Warranty provisions

The obligations agreed upon in the supply contract and the general terms and conditions of MAN, and the
statutory regulations valid at the time of concluding the contract shall be applicable.
Ignoring these instructions and any Operating Instructions of suppliers enclosed 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 genuine parts even after expiration of the warranty period in order to ensure
consistent performance of the engine.
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.
Information on the contact persons in charge can be retrieved whenever required via telephone, e-mail or
via the Internet. Address, see page LEERER MERKER.

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.
Additional safety instructions must be observed during the assembly and commissioning of the engine.
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 is used that is not specifically recommended by MAN, 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 safety of the product is not affected by the procedures that are used.
Most industrial accidents occur during the installation, operation, maintenance and repair of the products
and are caused due to non-compliance with basic safety regulations and protective measures. An accident
can often be avoided by recognizing potentially hazardous situations before an accident occurs.
An technician must be alert to potential hazards. The technician must also have the necessary training,
skills and tools in order to perform these works properly. The information in this publication was based upon
current information at the time of publication. Check for the most current information before you start any
job. The latest information can be provided by your MAN dealer.
2.1 Proper use
DANGER
Risk of damages to the engine due to improper use
Expiry of operating permit.
For this reason:
S Use the engine only for the approved application.
All engines described in these instructions are suitable for commercial operation and depending on the
type, suited to heavy, medium or light duty.
The operating mode is defined by the expected operating hours per year and the percentage of full load as
well as the average utilization.
An engine must only be installed for the specified application (e.g. fixed pitch propeller), for which it has
been certified and accepted.
The certification status can be found on the emissions type plate on the engine.
Any other use is classified as not in accordance with the designated use.
MAN accepts no liability for damage resulting from this. The operator alone shall bear this risk.
Proper use also includes compliance with the operating, maintenance and service work specified by the
manufacturer.
The engine must only be installed and put into service by personnel who are familiar with it and have been
instructed about potential dangers.
The manufacturer does not assume any liability for damage to property or personal injury resulting from
unauthorized modifications to the engine.
Tampering with the electronics and injection and control system 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.

2.2 Content of these instructions

Each person appointed to work on or with the engine must read and understand these instructions 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 these instructions 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 or the aftertreatment system that have not been expressly
approved by MAN.
If modifications are made without the written consent of MAN, any obligation of guarantee or warranty on
the part of MAN for damage and defects that are attributable to the unauthorized modification becomes null
and void. Moreover, MAN does not assume any liability for damage that are caused by modifications that
have not been approved.
2.4 Responsibility of the operating company

The operating company is subject to the statutory obligations of industrial safety.
In addition to the notices on industrial safety in these instructions, the safety, accident prevention and
environmental protection regulations applicable for the area of application of the engine must be obeyed.
In doing so, the following is particularly applicable:
S The operating company must be aware of the applicable provisions of industrial safety and it must
determine additional dangers in a risk assessment that may arise based on the special working
conditions where the engine is used. The operating company must implement these in the form of
operational instructions for operating the engine.
S During the total operating time of the engine, the operating company must check that the operating
instructions created by the company correspond to the current regulations and must adapt these
instructions if necessary.
S The operating company must clearly regulate and specify the responsibilities for installation, operation,
maintenance and cleaning.
S The operating company must ensure that all employees who work with the engine have read and
understood the operating instructions.
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 required protective equipment necessary for the personnel.
S These Operating Instructions must be kept near the engine and must be accessible to all persons
working with the engine whenever required.
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 it has been described in these instructions and in the maintenance instructions
completely and at the intervals specified, or have it done by a MAN service workshop / MAN authorized
partner.
S The operating company must have all safety equipment and devices checked regularly for
completeness and functionality.
S The information in the instructions must be followed completely and without any restrictions!

2.5 Requirements of personnel
2.5.1 Qualifications
WARNING
Risk of injury caused by untrained personnel
Ignoring the safety regulations poses the risk of injury to personnel.
For this reason:
S Carry out all work steps in accordance with the information in these instructions.
S Have the engine serviced and repaired only by trained personnel.
S Ensure that the engine cannot be started by unauthorized persons.
S Regular attendance at product and user training.
S Observe safety and accident prevention regulations.
S Ensure orderliness and cleanliness in the working area.
Tip for users

MAN Truck & Bus SE regularly provides product and application training. These training sessions can
provide the necessary expertise.
http://www.engines.man.eu/global/de/ueber-man-engines/man-engine-academy/Themen.html
The following qualifications are mentioned in the instructions for various areas of activity:
S A trained person
has been briefed about their assigned duties and informed about potential hazards in case of improper
conduct.
S Qualified personnel
are people who, based on their technical education, knowledge and experience as well as knowledge of
the relevant regulations, are capable of carrying out the duties assigned to them professionally.
S A qualified electrical technician
is someone who, based on his technical education, knowledge and experience as well as knowledge of
the relevant standards and regulations, is capable of working on electrical systems, identifying potential
hazards on his own and avoiding them.
The qualified electrical technician is trained for the special location where he is working and is familiar
with the relevant standards and regulations.
Only persons who can be expected to carry out their work reliably may be approved as personnel. Persons
whose reflexes are affected, e.g. by drugs, alcohol or medicines, are not approved.
S When choosing personnel, obey the regulations concerning age and profession applicable at the place
of work.
2.5.2 Unauthorized persons
WARNING
Risk of injury for unauthorized persons
For this reason:
S Keep unauthorized persons away from the working area.
S In case of doubt, talk to the persons and instruct them to leave the working area.
S Stop work as long as unauthorized 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 minimize the risks to health while working.
S Always wear the necessary personal protective equipment whilst carrying out any work.
S Obey the signs present in the working area regarding 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 jewelry on the body while working.
Hard hat
for protection against parts falling down or flying around.
Safety shoes
to protect against heavy falling parts and slipping on slippery surfaces.
Safety gloves
to protect hands from abrasion, getting pricked or deep injuries as well as from coming
into contact with hot or corrosive parts or liquids.
Clothing for special work

When doing special work, special protective equipment is necessary. Special reference is made to these in
the various chapters of these instructions.
Safety goggles
to protect the eyes from parts flying around and liquid sprays.
Ear protection
to protect against hearing loss caused by noise.

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 these
instructions in order to mitigate risks to health and to avoid hazardous situations.
Electrical current
DANGER
Risk of life from electrical voltage
For this reason:

S If the insulation of the voltage 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, deenergize the system and check that it is
deenergized.
S Shut off the voltage supply and secure it from being switched on again before completing
maintenance, cleaning or repair work.
S Do not bypass or disable any fuses. Replace fuses with those having the correct amperage rating.
S Keep moisture away from live parts. It can lead to a short circuit.
Moving components
WARNING
Risk of injury from freely rotating components
For this reason:

S During operation, do not reach into moving components or put your hands on moving components.
S Do not open covers during operation.
S Do testing and maintenance work only when the engine is completely stopped.
S Pay attention to the time delay: Before opening the covers ensure that parts are not moving any
longer.
S Wear close-fitting work clothing in the hazard zone.
Flying parts in the event of sudden engine damage
WARNING
Risk of injury from running engines
In case of damage to engines, components may fly through the engine room at a high level of energy
and injure persons in the immediate vicinity.
For this reason:
S No one is allowed in the engine room when the engine is running.

Exhaust gases
WARNING
Health hazard due to a leaky exhaust system
For this reason:

S Decommission machines with leaking exhaust systems immediately.
S Repair leaking exhaust system.
S Ensure adequate ventilation.
Easily inflammable materials - diesel fuel, oils and greases
WARNING
Risk of injury from easily inflammable substances
Risk of fire from highly flammable materials, liquids and gases.
For this reason:
S Smoking is forbidden in the hazard zone.
S Working with open flames and sources of ignition in the hazard zone is forbidden.
S Keep fire extinguishers ready for use.
S Report suspicious substances, liquids or gases immediately to the person in charge.
S Discontinue work immediately in case of fire. Leave the danger zone until given the all clear.
Coolants - antifreeze and anti-corrosion agent
WARNING
Risk of injury from coolants harmful to health
Coolant contains substances that are harmful to health.
For this reason:
S Observe and follow the safety data sheets of the manufacturers.
S Wear personal protective equipment.
S Avoid contact with the eyes and skin.
S Avoid spilling and mist formation.
Hot service products
CAUTION
Risk of scalding by hot service products
Service products reach high temperatures and cause burns.
For this reason:
S Allow service products to cool down.
S If necessary, wear additional ear protection, a safety mask, safety goggles, and chemical-resistant
gloves.
S In the event of injury, consult a doctor immediately.
S Observe safety data sheets.
S Follow the accident prevention regulations.
S Observe workplace safety regulations.

Hot surfaces
CAUTION
Risk of burn injuries caused by hot surfaces
Components reach high temperatures during operation and cause scalding if they come into contact.
For this reason:
S Wear personal protective equipment and safety gloves.
S Allow components to cool down to ambient temperature.
S Ensure that protective devices is never removed from hot components.
Noise
WARNING
Risk of hearing impairment caused by noise
For this reason:

S Always wear ear protection while carrying out any work.
S Remain in the hazard zone only as long as necessary.
Sharp edges, pointed corners, dirt or objects lying around
CAUTION
Risk of injury from disregarding accident prevention regulations
For this reason:


Work on the Common Rail system
CAUTION
Risk of injury from escaping liquids
Liquid jet gets released under high pressure.
For this reason:
S Wear additional hearing protection, a safety mask, and protective googles.
S Shut down the engine and wait until the pressure has fallen before starting work.
S Observe accident prevention regulations.
CAUTION
Risk of life from defective lines
Liquid jet gets released under high pressure.
For this reason:
S Never touch the liquid jet.
S Shut down the engine immediately.
S If necessary, initiate further measures to reduce the pressure and stop the liquid jet.
S Absorb liquids that have leaked out properly and arrange for their disposal.
S Replace defective parts.
DANGER
Risk of life from strong magnetic fields
For this reason:

S Persons with pacemakers must not stay near the engine.
S Persons with metallic implants must not stay near the engine.
S Keep ferromagnetic materials and electromagnets away from the magnetic source
(minimum distance: 3 m).
S Put metallic objects (jewelry, 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.

Hydraulic System
WARNING
Risk of injury from hydraulic sources
For this reason:
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-pressurize it.
S Relieve the pressure tank completely. Check for depressurized condition.
S Do not change pressure settings beyond the maximum values.
S Wear chemical-resistant safety gloves.
Cable harnesses and plug connectors
NOTICE
Risk of damage to components caused by incorrect handling
Irreparable damage to plug connectors and EDC control units from spread contacts and damaged
contacts.
For this reason:
S When installing, the plug first open the plug lock completely and then insert the plug connector and
lock it.
S Protect removed plug connectors and contacts against dirt.
S Check cable harnesses and plug connectors only with a suitable test device (bushing box).
S Connect/disconnect the plug connectors of electronic control units only when the ignition is switched off.
Electric welding
NOTICE
Risk of material damage due to incorrect handling of welding equipment
Damage to components and the electronics system due to electric arc welding.
For this reason:
S Welding works of any kind may be carried out only after consultation with the system supplier or as
per his specifications.
S MAN shall not assume any liability for damages, especially to the engine electronics, that occur due to
improperly performed welding works.

2.8 Safety equipment
The operating company must retrofit the following safety equipment:

Install emergency-stop device before the engine is put into operation and link to the system’s safety chain.
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.
DANGER
Risk of life from non-functional safety equipment and devices
For this reason:

S Before beginning work, check whether all safety equipment is functional and correctly installed.
S Prior to starting the engine, check whether all safety equipment is functional and correctly installed.
S Never disable safety equipment or devices during operation.
2.9 Protective devices
The operating company must retrofit the following protective devices:

The V-belt cover included in the scope of supply is not a protective device. Before putting the engine into
operation, suitable protective devices must be implemented.
DANGER
Risk of life due to inadequate protective devices
The V-belt cover included in the scope of supply is not a protective device.
For this reason:
S Implement suitable protective devices before putting the engine into operation.

2.10 Conduct in the event of hazards and accidents
Preventive measures
S Always be prepared for accidents or fire!
S Keep first-aid equipment (first-aid box, blankets, etc.) and fire extinguishers readily accessible.
S Check the first-aid equipment and fire extinguishers regularly for completeness and functionality.
S Familiarize persons with accident reporting, first-aid and rescue equipment.
S Conduct training and drills on safety regularly.
S Keep entry routes clear for ambulance vehicles.
CAUTION
Improper conduct may pose a safety hazard
For this reason:

S Remain calm in the event of an accident.
S Shut down the engine.
S Initiate first-aid measures
S Raise an alarm with ambulance and / or fire department.
CAUTION
Risk of injury from harmful service products
For this reason:

S If necessary, wear additional hearing protection, a safety mask, protective goggles, and chemical-
resistant safety gloves.
S Avoid contact with the eyes and skin.
S Do not eat, drink or smoke at the workplace.
S Wash hands thoroughly when finished working.
S Remove contaminated clothing immediately.
S Avoid any spillage of service products.
S Observe safety data sheets.
S Use an extraction system as required.
CAUTION
Risk of injury from disregarding accident prevention regulations
For this reason:


2.11 Signage
The following icons should be placed near the hazard zone.
WARNING
Risk of injury from illegible icons
Over time, stickers and icons get dirty or become illegible in some other way.
For this reason:
S Make sure all safety, warning and operational notices or instructions are always clearly legible.
S Clean or replace illegible safety, warning and Operating Instructions.
No trespassing
Areas designated in this manner may not be entered.
Electrical voltage
Only electricians may carry out work in working areas marked in this manner.
Unauthorized 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.
Risk of life from suspended loads

During hoisting operations, loads may sway outwards and fall down. This may cause
severe injuries right up to death.
Follow the instructions

The instructions must be read and understood fully prior to any work being started.
The work may only be performed by personnel in accordance with the section on per
sonnel requirements.

2.12 Environmental protection
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 country-specific safety regulations.
S Use appropriate and suitably sized containers to collect service products.
S Store service products only in original containers.
S Use suitable binders to absorb leaking service products and dispose of the waste properly.
S If required, inform the municipal authorities in charge about the damage.
S Run cleaning fluid and rinse water through an oil separator with sludge trap.
The following substances harmful to the environment are being used:
Lubricants
Lubricants such as greases and oils contain toxic substances and other substances that are harmful to the
environment. They should not reach the environment. Disposal must be carried out by a professional
disposal company specialized in disposal.
Diesel fuel
Diesel fuel contains toxic substances that are harmful to the environment. It should not reach the
environment. Disposal must be carried out by a professional disposal company specialized in disposal.
Coolant
Coolants may contain toxic and other substances harmful to the environment. They should not reach the
DEF/AUS32/AdBlue ®
DEF/AUS32/AdBlue® contains substances that are harmful to water. They should not reach the


Engine type plate
3 Engine type plate
Always mention the engine type, engine number

and the factory number / order number in all
communication and enquiries.
Hence, read the corresponding information from
the engine type plate and enter it below.
The engine model labels (1) and (2) are fastened
on the crankcase.
Engine type (3)
......................................................................
Engine number (4)
......................................................................
Factory number / order number (5)
......................................................................
Engine type plate
3.1 Explanation of engine no. (Engine identification number)

Classification key 1 2 3 4
Engine no. XXX XXXX XXX XXXX
1 Type number according to the model code
2 Day of assembly (factory-internal specification)

3 Assembly sequence (sequence number on the day of assembly)
4 Production-related and equipment-specific information
3.2 Explanation of the model name

Model name Explanation Example
D Fuel type Diesel
26 Figure + 100 126 mm bore
7 Lifting performance indicator (rounded) 166 mm stroke
6 Number of cylinders 6 cylinders
L Turbocharging with turbocharging and
charge-air cooling
E Engine for installation Marine engine
4.. Type of application Marine engine
3.3 Emission label
The emission label (1) is located on the housing of

turbocharger.
The required Emission Control Information label
has been placed on this certified engine during the
assembly process.
Engine type plate
3.3.1 Duplicate emission label
If the emissions type plate is made illegible or it is

covered during the installation of the engine into
the system, thereby making it impossible to read
during routine maintenance, a duplicate type plate
must be attached to the system, according to
- US EPA, s. 40 CFR 1068.105 (c)
- EU regulation 2016/1628, Article 15 (4)
If necessary, MAN will supply the quantity of
replacement type plates. Send a written request
with the following information to MAN if you need
to attach a replacement type plate:
S Identification of the family (from the original
engine type label).
S The reason why you need a replacement type
plate for your model
S The number of replacement type plates needed
MAN will retain the following records for at least
eight years.
S Your written requests, documentation and
descriptions
S Number of replacement type plates sent
by MAN
All unused or unnecessary duplicate model labels must be destroyed.
Body and function
4 Body and function
4.1 Application areas of the engines

The marine diesel engine D2676 LE4.. is suitable for driving ships.
For the assignment of the engine types to the approved operating modes refer to the Technical
Specifications starting from page 95.
Typical use
Light-duty operation: Yachts, patrol boats and maritime distress rescue
Heavy-duty operation: Trawlers, tugboats, freight ships and ferries
Medium-duty operation: Pilot vessels, passenger ships and ferries, and patrol boats
4.2 Engine body and engine equipment

The D2676 LE4.. engines are 6-cylinder 4-stroke diesel engines with exhaust gas turbocharging and
charge-air cooling.
Injection system
High-pressure injection system common rail in conjunction with EDC17 (Electronic Diesel Control).
Fuel system
Low-pressure system consisting of fuel lines, the hand priming pump and the switchable (only classified
engines) fuel filters.
High-pressure system consisting of the flow-controlled high pressure pump with a fuel feed pump attached
at the flange as well as the pressure pipe with rail pressure sensor, pressure-limiting valve, high-pressure
lines and the injectors.
Engine lubrication
The engine is lubricated by forced-feed lubrication for all bearing points. The engine oil filter and the oil
cooler are grouped together as an oil module. The oil level is measured in the oil pan with the help of an oil
dipstick and oil level sensor that is installed in the block.
Classifiable engines are supplied with switchable oil filters.
Cooling system
The engine is liquid-cooled. The cooling system is designed as an excess pressure system. The cooling
circuit is a thermostat-controlled forced circulation cooling system with a maintenance-free coolant pump
driven by a ribbed V-belt. The distributor housing enables the coolant pump to be accommodated. Heat
exchangers and charge-air coolers are cooled using sea water.
The gear drive of the marine pump is attached to the block.
Body and function
Intake and exhaust system

The intake air reaches the exhaust gas turbocharger via the air filter. The charge air now compressed is
cooled while flowing through the charge-air cooler before it is fed to the engine.
The exhaust gas pipe and the hull of the exhaust gas turbocharger are cooled by the engine coolant.
Flywheel housing and flywheel

The flywheel housing is designed with a connection according to SAE1.
Depending on the type of application, different flywheel designs, e.g., for connecting a gearbox
at the flange or for attaching an elastic propshaft clutch can be supplied.
Starter
The electric starter is designed as an insulated two-pole unit.
Alternator
The alternator is electrically insulated when mounted.
4.3 Classification
Frequently, ships for commercial operation are subject to the regulations of a classification society. The
safety standards of this classification society have then to be satisfied in the construction and equipping of
the ships concerned.
These safety standards relate, among other factors, to the dimensioning, layout and construction of the
mechanical systems, so that:
S Failures due to overloading are avoided,
S The risk of fire is minimised,
S Accidents involving injury to persons during operation and maintenance are prevented.
Classifiable engines are therefore factory-fitted with the specified safety equipment,
e.g. switchable fuel and oil filters, leak-proof injection lines etc.
Body and function
4.4 Engine views

Depending on the scope of delivery, the engine can also be equipped with a flat oil pan (see installation
drawing) and/or hull-mounted cooling system.
4.4.1 View from the front left - classified engine
(1) Power take-off drive (PTO) (5) Alternator

(2) Charge-air cooler (6) Cover Vibration damper
(3) Marine pump (7) Expansion tank
(4) High pressure pump
Body and function
4.4.2 View from behind right - classified engine
(1) Oil module (5) Flywheel

(2) Switchable oil filter (6) Exhaust gas manifold in accordance with ATL
(3) Fuse box (7) Air filter
(4) Engine mount
Body and function
4.4.3 View from the front left - non classified engine
(1) Charge-air cooler (5) Alternator

(2) Power take-off drive (PTO) (6) Cover Vibration damper
(3) Marine pump (7) Expansion tank
(4) High pressure pump (8) Engine cover (optional)
Body and function
4.4.4 View from behind right - non classified engine
(1) Crankcase ventilation (5) Flywheel

(2) Oil module (6) Exhaust gas manifold in accordance with ATL
(3) Fuse box (7) Air filter
(4) Engine mount (8) Oil dipstick (optionally left or right)
Transport, packing and storing
5 Transport, packing and storing

It is essential that the “Installation Instructions” be followed when installing a new or overhauled engine.
Tip for users

Installation and commissioning to be carried out only by employees of the manufacturer of the complete
system or by persons authorized by him.
5.1 Requirements
Before starting the work, read and follow the general safety instructions and the safety instructions given
in this chapter.
Follow the instructions in all cases and proceed with care in order to prevent accidents, personal injury
and material damage.
Personal protective equipment

The following protective equipment must be worn:
S Industrial protective clothing
S Safety helmet
S Safety shoes
S Safety gloves
5.2 Safety instructions
Suspended loads
DANGER
Risk of life from handling transport goods incorrectly
The transport package can sway out, tilt and/or fall down.
For this reason:
S Have the engine transported only by trained personnel.
S Ensure that during transport, no persons, objects or obstacles are located in the swivel range of
the transport package.
S Move loads only under supervision.
S Use only approved hoists with adequate load-bearing capacity.
S Do not use any torn or chafed hoists such as cables and belts.
S Do not place hoists such as cables or belts on sharp edges and corners, do not put knots in them
and do not twist them.
S Use the lifting eyes only for transporting the engine without attachments.
S Pay attention to the markings and information about the center of gravity on the packages.
S While transporting with the crane, sling the crane hook in such a manner that it lies above the center
of gravity of the package.
S Lift the package carefully and observe whether it tilts. If necessary, change the slinging point.
S Handle transport packages carefully and pay attention to the icons and instructions on the package.
S Cables and chains must exert vertical tension (tolerance: 5°) on the crane hooks.
S Prohibit unauthorized transport or the placing/removing of transport aids.
S Do not step on the engine covers.
S Set the load down when leaving the workplace.
Read this manual carefully before starting any work!

This is particularly applicable to the chapter “General Safety Instructions”
NOTICE
Risk of property damage from improper transport
Transport packages may fall or turn over as a result of improper transport.
For this reason:
S Proceed cautiously when off-loading the transport packages upon delivery as well as during transport
within the facility.
S Pay attention to the icons and instructions on the package.
S Use only approved hoists with adequate load-bearing capacity.
S Do not use any torn or chafed hoists such as cables and belts.
S Do not place hoists such as cables or belts on sharp edges and corners, do not put knots in them
and do not twist them.
S Use the lifting eyes only for transporting the engine without attachments.
S Pay attention to the markings and information about the center of gravity on the packages.
S While transporting with the crane, sling the crane hook in such a manner that it lies above the center
of gravity of the package.
S Lift the package carefully and observe whether it tilts. If necessary, change the slinging point.
S Cables and chains must exert vertical tension (tolerance: 5°) on the crane hooks.
S Set the load down when leaving the workplace.

5.3 Transport inspection

Check the delivery for completeness and transit damage on receipt.
Proceed as follows in case of externally identifiable transport damage:
S Do not accept the shipment or accept it conditionally.
S Note the scope of damage on the transport documents or on the packing slip of the carrier.
S Register a complaint.
Tip for users

File a complaint about each defect as soon as it is identified. Claims for compensation can be enforced
only within the applicable periods for registering complaints.
5.4 Packaging
About the packaging

The individual packages must be packed appropriately for the expected conditions of transport.
The packaging should protect the individual components from transport damage, corrosion and other types
of damage until the time of assembly/installation. Therefore, do not destroy the packaging, and remove it
only just prior to assembly/installation.
Handling packaging materials

Dispose of the packaging material in accordance with applicable statutory regulations and local regulations.
Improper disposal of packaging materials may endanger the environment
For this reason:
S Dispose of the packaging materials in an environmentally friendly manner.
S Observe and follow the local regulations for disposal. If necessary, hire a professional company for
disposal.
5.5 Storage
Storing the packages

Store the packages under the following conditions:
S Do not store them outdoors.
S Store them so that they are dry and dust-free.
S Do not expose them to corrosive media.
S Protect them from sunlight.
S Avoid mechanical vibrations.
S Storage temperature: 15 to 35 °C.
S Relative humidity max. 60 %.
S For storage exceeding 3 months, check the general condition of all parts and the packaging.
If necessary, replenish or reapply the preserving agent.
Tip for users

In some cases, there are instructions on the packages for storage that go beyond the requirements
mentioned here. Comply with these accordingly.

5.6 Transport
5.6.1 Engine without gearbox
Slinging points for transport using a crane
There are 2 crane hook eyelets (3) and (4) attached to the engine to lift it.
Use adequately dimensioned crane-lifting gear (1) to lift the engine!
Cables and chains must exercise vertical pull (tolerance 5°) on the crane hooks.

5.6.2 Engine with gearbox
Slinging points for transport using a crane
There are 2 crane hook eyelets (3) and (4) attached to the engine to lift it.
Use adequately dimensioned crane lifting gear (1)!
Cables and chains (2) must exercise vertical pull (Tolerance 5°) on the crane hooks!

Transporting with the crane

The engine may be transported with a crane under the following conditions.
S The crane and lifting gear must be designed for the weight of the engine.
S The operator must be authorized to operate the crane.
► Attach cables, belts or multi-point suspension gear in accordance with the diagram.
► Ensure that the transport package is hanging straight and, if necessary, pay attention to the eccentric
center of gravity.
► Start transport.
Transporting with the forklift

The engine may be transported with a forklift under the following conditions.
S The forklift and hoisting gear must be designed for the weight of the engine.
S The engine must be fixed securely on the pallet.
S The forklift driver must be qualified and authorized to drive the forklift.
► Drive the forklift between or below the runners of the pallet.
► Drive the fork until it projects from the opposite side.
► Make sure that the pallet cannot tilt if the center of gravity is not in the middle.
► Lift the pallet with the transport package and begin transport.


Installation and Commissioning
6 Installation and Commissioning
6.1 Requirements
Before starting the work, read and follow the general safety instructions and the safety instructions given
in this chapter.
Follow the instructions in all cases and proceed with care in order to prevent accidents, personal injury
and material damage.

S Safety shoes
S Safety gloves
Personnel
Installation and commissioning should be done only by MAN employees or specialists trained by MAN.
NOTICE
Risk of damage to the engine due to improper installation/commissioning
For this reason:

S Install the components properly.
S Maintain the prescribed screw-tightening torque.
S Commissioning is done only by trained specialists.
S Secure components so that they do not fall down or turn over.
Basic rules
WARNING
Risk of injury from improper installation and commissioning
For this reason:
S Ensure adequate room for assembly before beginning the work.
S Proceed cautiously with exposed and sharp-edged components.
S Install the components properly.
S Maintain the prescribed screw-tightening torque.
S Secure components so that they do not fall down or turn over.
S Carry out all work steps in accordance with the information in this manual.
S Before commissioning the engine, read the manual carefully and make sure that you are familiar
with the “critical” areas.
S For safety reasons, we recommend that the entry to the engine room be marked with an “No entry”
sign and that operating personnel be informed that they are responsible for the safety of individuals
who enter the engine room.
6.3 Installing the engine

Installation of the engine, i. e. connecting the energy source or connecting the cooling system, must be
carried in accordance with information from the manufacturer of the overall system and with the aid of
the respective installation instructions.
6.3.1 Interfaces between the engine and system
(1) Power take-off (4) Fuel system

(2) Sea water entry (5) Alternator
(3) Charge air cooling system
During installation of the engine, the following installation work needs to be carried out on the interfaces
between the engine and the system:
(1) Connect Power take-off/Hydraulic pump, see page 64
(2) Connect sea water circuit, see page 50
(4) Connect the fuel system, see page 54
(1) Sea water outlet (5) Flywheel

(2) Cab heating (optional) (6) Exhaust gas system
(3) Lubrication oil system (7) Intake system
(4) Engine mount
During installation of the engine, the following installation work needs to be carried out on the interfaces
between the engine and the system:
(1) Connect sea water circuit, see page 50
(2) Connections of cab heating, see page 63 (optional)
(4) Installation of the elastic engine mount, see page 49
(5) Attach the clutch / gearbox, see page 47
(6) Attach the exhaust gas system, see page 61
6.3.2 Installation drawing
Tip for users

The basis for installing the engine are the installation instructions and installation drawing.
6.3.3 Bolted connections
NOTE
Risk of components damage from improperly tightened threaded connections
Therefore:
S Use the impact screwdriver with max. 50 % of the final torque value specified.
S The final tightening must always be done with the torque wrench.
Torques for bolted connections, see page 69.
6.4 Completing the engine and assembling the unit

Refer to the installation drawing for the dimensions of the flywheel housing and the flywheel as well as the
type of threads for attaching the clutch.
6.4.1 Accessibility to the E-box

See Operating Instructions „MAN Intelligent Marine Safeguard System“ (iSea / iSea Class)
6.4.2 Attachment of an alternator to the flywheel housing
Flywheel
The connecting dimensions of the flywheel (1) are

specified in the installation drawing.
S Remove oil, grease and preserving agents from
the flywheel.
Flywheel housing
Tip for users

Bolt tightening torques, see page 69.
The installation drawing provides information about
the dimensions of the flywheel housing (1) and the
type of screw connections.
6.4.3 Check the axial clearance of the crankshaft
NOTICE
Danger of engine damage from clutches and attachments
For this reason:

S The axial clearance of the crankshaft of the engines structurally specified must not be reduced.
S Check the axial clearance of the crankshaft.
Special tools
[1] Dial gauge bracket 08.71082-0005

S Check the axial clearance of the crankshaft in conjunction with:
S Dial gauge
[2] Dial gauge 08.71000-3217

S Check the axial clearance of the crankshaft in conjunction with:
S Dial gauge bracket
► Place the dial gauge bracket [1] (1) with the dial
gauge [2] (2) on the engine such that the tracer
pin of the dial gauge is under tension on the
vibration damper
► Press the crankshaft in the axial direction to the
flywheel housing until the contact surface (stop)
► Set the dial gauge to zero
► Pull the crankshaft in the axial direction from
the flywheel housing until the contact surface
(stop)
► Read the value displayed on the dial gauge
Axial clearance of the crankshaft . . 0,20-0,40 mm
If the axial play is outside tolerance or if the
crankshaft springs back after sliding it, the
attachment must be checked.
6.5 Installing the drive system in the ship
6.5.1 Install the elastic engine and gearbox mounts

The maximum adjustable height of all mounts is 10 mm. This adjustment height cannot be exceeded.
Larger differences in height must be compensated by backing plates.
The less the adjustment height can be adjusted, the more spare height is available for subsequent
readjustments. The drive system must be adjusted prior to commissioning, see the installation instructions.
The elastic mounts can be supplied by MAN.

Refer to the layout drawings for the dimensions of
the mount and the drilling pattern. This is available
with MAN, see page 2 for the contact address.
(1) Mounting bolts M 20,
Property class 8.8
(2) Screws of the transport lock
(3) Height adjustment
(4) Mounting bolts for engine base M 20
S Place the drive system with elastic mounts on
the engine foundation. Pay attention to the
correct arrangement of the mounts (Shore
hardness).
S Screw the engine base and the gearbox base
together with the elastic mounts.
Arrangement of elastic engine mounts

Engine type MAN part number Shore hardness
D2676 LE4XX 51.96210-7051 65
Elastic mounts for flange-mounted integral V-gearbox
(1) Mounting bolt for gearbox base M 20

(2) Height adjustment
(3) Bolts for transport safety device
(4) Mounting bolts M 20,
Strength class 8.8
Arrangement of elastic engine mounts

Engine type MAN part number Shore hardness
D2676 LE4XX 50.96210-7000 55
6.6 Connecting the cooling system
6.6.1 Connect the sea water lines for engine cooling
Single-circuit cooling system via plate heat exchanger
The installation drawing provides information about

the design of the coolant connections.
S Connect the coolant inlet (1)
S Connect the coolant outlet (2)
Tip for users

Suction nozzle (1) is rotatable.
For engines without seawater pump:
S Connect the sea water inlet on intercooler

A = 52 mm
B = 106 mm
C = 2 x M8 threaded hole
Two-circuit cooling system for external skin cooling
Connections on the engine for the high-temperature circuit
(1) Engine inlet from the cooling system

(2) Engine outlet to the cooling system
(3) Filler pipe from expansion tank to coolant pump
for high-temperature circuit
Connection (3) optionally: Depending on
version (with/ without cabin heating)
(4) Vent line from engine to expansion tank

(primary) or
Connection (5): Alternative
(option 1)
(option 2)
Connection as shown on figures Hose connector to Inside ∅ Outside ∅

Works Standard mm mm
(1) Engine inlet from the cooling system 55 60
(2) Engine outlet to the cooling system (option 1) 55 60
(option 2) 53 60
(3) Filler pipe from expansion tank to coolant M3103-3 11 15
pump for high-temperature circuit, DN15
(4) Vent line from engine to expansion tank, M3103-3 3,5 10
M14x1.5 (DN10)
Connections on the engine for the low-temperature circuit
(1) Filler pipe from expansion tank to coolant pump

for low-temperature circuit
(2) Coolant inlet from the cooling system
(3) Coolant outlet to the cooling system
(4) Vent line from intercooler to expansion tank
Connection as shown on figures Hose connector to Inside ∅ Outside ∅

Works Standard mm mm
(1) Filler pipe from expansion tank to 9 15
coolant pump for low-temperature circuit
(2) Coolant inlet from the cooling system M3103 65-67 75
(3) Coolant outlet to the cooling system 65 75
(4) Vent line from engine to expansion tank, DN10 7 10
Cable harness for MAN expansion tank
Position 1 - 4 are supplied separately.

(1) MAN expansion tank
(2) Coolant pressure sensor
(3) Coolant level sensor
(4) Cable harness adapter (length 5,5 m)
(5) Connection engine cable harness
6.6.2 Additonal cooling water supply of other components
The cool water supply of the gearbox oil cooler

takes place via the connection (1) to the sea water
pump.
S Connect the sea water connection for
the gearbox oil cooler inlet (1) (supply)
S Connect the sea water connection for
the gearbox oil cooler outlet (2) (return)
Alternative:
Take the seawater at the connection (2) and conduct after the gearbox oil cooler outwards.
► Limit the max. flow with orifices.
For the engine cooling must flow through the heat exchanger at least xxx liters / min!
6.7 Connect the fuel lines
6.7.1 Connect the fuel lines
S Unscrew the sealing plugs

S Connect the fuel supply (1)
S Connect the fuel return flow (2)
Connection of fuel supply (1):
Screw neck . . . . . . . . . . . . . . . . . . . . . . . . . . M22x1.5
Connection of fuel return flow (2):
Screw neck . . . . . . . . . . . . . . . . . . . . . . . . . . M22x1.5
Fittings for fuel connection:
(3) Hoselines (M22x1,5)
(4) Fittings (M22x1,5/M18x1,5)
(included in MAN's scope of delivery)
6.7.2 Installing fuel pre-filter and hand pump - classified engines

Fuel pre-filter and hand pump for non classified engines, see page 58
NOTICE
Risk of property damage due to dirt particles
Risk of components getting damaged by impurities in the fuel system
For this reason:
S Be sure to maintain the utmost cleanliness when working on the fuel system.
Installing fuel pre-filter and hand pump
The fuel pre-filter with water separator should not

be attached directly to the engine since the engine
vibrations may degrade the water separation.
Hole pattern fuel pre-filter:
Dimension X . . . . . . . . . . . . . . . . 124 mm
Dimension Y . . . . . . . . . . . . . . . . 390 mm
Dimension Z . . . . . . . . . . . . . . . . 9 mm
Mounting bolts: Hex screws or cylinder screws,
each with washers
(1) M8x30 (2x)
(2) M8x50 (2x)
(3) Spacer bush:
internal diameter . . . . . . . . . . . . Ø 9 mm
External diameter . . . . . . . . . . . Ø 18 mm
Length . . . . . . . . . . . . . . . . . . . . . 35 mm
Hole pattern hand pump:

Dimension A . . . . . . . . . . . . . . . . 17 mm
Dimension B . . . . . . . . . . . . . . . . 46 mm
Bore C . . . . . . . . . . . . . . . . . . . . 8.5 mm
Mounting bolts . . . . . . . . . . . . . . M8x60 (4x)
Installing fuel pre-filter and hand pump
NOTE
The fuel pre-filter is only classifiable with
protective plate
Therefore:
S Install protective plate on the fuel pre-filter.
The protective plate (X) must be installed by

the genset builder/shipyard.
(1) Selector lever
(2) Fuel inlet (from tank to filter)
(3) Fuel outlet from filter (to inlet (6) hand
priming pump)
(4) Filter cartridge
(5) Water drain plug / water level sensor
(6) Fuel inlet (from filter)
(7) Fuel outlet (to engine)
Bolted connections for fuel pre-filter:
Connection (2):
- sealing ring (for M18)
- socket (M18x1.5/M22x1.5)
Connection (3):
- socket (M18x1.5/M22x1.5)
Bolted connections for hand pump:
Connection (6):
- socket (M18x1.5/M22x1.5)
Connection (7):
- socket (M18x1.5/M22x1.5)
Lever position:
1st Both filters in operation
(operating position)
2nd Left filter in operation
3rd Right filter in operation
Connecting cable (adapter)
(1) Length 120 ± 20 mm (3) Length 60 ± 20 mm

(2) Length 500 +50 mm (4) Length 4600 ± 200 mm
The water level in the water collection chamber of the fuel prefilter is monitored by sensors. The fuel
prefilter plugs (3) are to be connected to the plugs T1 and T2 of the engine wiring harness.
Technical specifications:
Supply voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Current consumption (switch): . . . . . . . . . . . . . . max. 10 mA
Current consumption (WIF-sensor): . . . . . . . . . max. 25 mA
Temperature resistance
Operating temperature: . . . . . . . . . . . . . . . . . . . . -25 °C up to 85 °C
Storage temperature: . . . . . . . . . . . . . . . . . . . . . . -40 °C up to 95 °C
6.7.3 Installing fuel pre-filter and hand pump - non classified engines
Fuel pre-filter and hand pump for classified engines, see page 55
NOTE
There is the risk of damage to property caused by dirt particles
Risk of components getting damaged by impurities in the fuel system
Therefore:
S Pay attention to utmost cleanliness when working on the fuel system.
Mount the fuel pre-filter
The fuel pre-filter with water separator should not

be attached directly to the engine since the engine
vibrations may degrade the water separation.
Hole pattern fuel pre-filter:
Dimension X . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Dimension Y . . . . . . . . . . . . . . . . . . . . . . . 53 mm
Dimension Z . . . . . . . . . . . . . . . . . . . . . . . 313 mm
Bore/ long hole . . . . . . . . . . . . . . . . . . . . . Ø 11 mm
Sufficient space must be available to trap the
water separated and to change the filter cartridge
(H approx. 200 mm).
Mount the hand pump

Hole pattern hand pump:
Dimension X . . . . . . . . . . . . . . . . . . . . . . . 42 mm
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ø 8,7 mm
Stroke height:
Dimension Y . . . . . . . . . . . . . . . . . . . . . . . 50,1 mm
max. stroke height . . . . . . . . . . . . . . . . . . 94,1 mm
Removal height:
Dimension Z . . . . . . . . . . . . . . . . . . . . . . . 52 mm
max. removal height for filter insert . . . 97 mm
Max. bending range of the axis

of pump cylinder . . . . . . . . . . . . . . . . . . . 20°
Connect the fuel pre-filter and hand pump
Each choose a connection at position (1), (2)

and (3).
Opposite side must be closed.
(1) Fuel inlet (from the tank to the filter)
(2) Fuel outlet (from the filter to the inlet (6) of the
hand pump)
(3) Fuel outlet (to the engine)
(4) Filter cartridge
(5) Water drain plug / Water level sensor
Fittings for pre-filter:

Choose connection (1):
- Sealing ring (for M18)
- Fitting (M18x1,5/M22x1,5)
Opposite side must be closed.
Fittings for hand pump:

- Adapter fitting (M14x1,5/M18x1,5)
Opposite side:
- Screw plug (M14x1,5)
Connection (6):
Connecting cable (adapter)
(1) Length 5100 +200 mm (3) Length 60 ± 20 mm

(2) Length 120 ± 20 mm
The water level in the water collection chamber of the fuel prefilter is monitored by a sensor. The fuel
prefilter plug are to be connected to the plug A1 of the engine wiring harness.
Technical specifications:
Supply voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Current consumption (switch): . . . . . . . . . . . . . . max. 10 mA
Current consumption (WIF-sensor): . . . . . . . . . max. 25 mA
Temperature resistance
Operating temperature: . . . . . . . . . . . . . . . . . . . . -25 °C up to 85 °C
Storage temperature: . . . . . . . . . . . . . . . . . . . . . . -40 °C up to 95 °C
6.8 Exhaust gas system
6.8.1 Exhaust gas outlet at the engine

The exhaust manifold is uncooled and therefore must be isolated during installation togehter with the
vessel´s exhaust system. The insulation can be attached and sealed to the flange of the outer shell of
exhaust turbocharger.
Tip for users

Dimensions of the flange for connecting the exhaust system on the ship side, refer to the installation
drawing.
NOTE
Danger of damage to the engine caused by water hammer
Engine damage
Therefore:
S Install pipe elbows with the following exhaust gas line (“gooseneck”) in the pipeline.
The exhaust gas manifold for the exhaust gas outlet can be optionally mounted in three position:
exhaust gas outlet behind

(1) Flange of the outer shell of turbocharger
(2) Exhaust manifold (uncooled)
exhaust gas outlet at 45°
Exhaust gas outlet upwards
6.8.2 Connecting the exhaust gas system to the engine
Between the engine and the exhaust gas system

elastic connecting elements must be installed,
which permit engine movements caused by the
elastic engine mount and decouple the engine on
the vibration side from the exhaust gas system.
Example: Compensator (1)
NOTE
Component damage by the action of force on the turbocharger.
Therefore:
S Exhaust gas lines must be mounted in such a manner that no forces act on the turbocharger.
6.9 Connect the cab heater
Anwendertipp
For engines with two alternators, the connecting parts are supplied loose.
Heater return flow to the coolant pump
(1) Pipe 18x1.5, inside diameter 15 mm

(2) Screw connector M26x1.5
(3) Screw plug M26x1.5
Heater supply at the coolant manifold
(1) Pipe 18x1.5, inside diameter 15 mm

(2) Screw connector M26x1.5
(3) Screw plug M26x1.5
6.10 Power take-off/Hydraulic pump
The engines can be equipped with a power

take-off on the side of the crankcase. A hydraulic
pump (1) can be attached there.
Power is transmitted via a clutch sleeve with
internal gearing.
If no hydraulic pump is attached at the factory, the

power take-off is closed off with a blind flange (2).
6.10.1 Hydraulic pumps

Hydraulic pumps are available for clockwise and anti-clockwise directions of rotation. They may only be
used for the indicated direction of rotation. The direction of rotation is defined with respect to the shaft.
Overview of hydraulic pumps
MAN item number Direction of rotation Continuous pressure Delivery volume

bar cm3 / revolution
51.38600-7007 clockwise 250 8
51.38600-7009 clockwise 276 8
51.38600-7008 clockwise 250 11
51.38600-7010 clockwise 276 11
51.38600-7017 clockwise 200 16
6.11 Electrical system
6.11.1 Starter
NOTE
Component damage caused by corrosion
Therefore:
S The minus cable of the starter battery must be routed back to the starter terminal 31.
S Connect the engine and all pipe connections from and to the engine by “earthing cable” with the ship
potential.
In multi engine systems, independent wiring is necessary for each engine, i.e. the circuits of the engines
should not be combined with one another.
Batteries
Separate batteries for the starter must be provided for each engine. Separate on-board 24 V DC loads
must be supplied with separate batteries.
Starter
The starter is designed with two poles for all MAN
marine engines. This is why the plus cable of the
starter battery must be connected to terminal 30 of
the starter (1), and the minus cable of the starter
battery must be connected to terminal 31 of the
starter (2).
The minus cable should never be connected to
the ship potential, the ship's rear section or other
components.
Connection dimensions, terminal 30 (1)
Connection thread: . . . . . . . . . . . . . . . . . . . M10x1.5
Tightening torque: . . . . . . . . . . . . . . . . . . . 20-24 Nm
Connection dimensions, terminal 31 (2)
Connection thread: . . . . . . . . . . . . . . . . . . . M10x1.5
Tightening torque: . . . . . . . . . . . . . . . . . . . 20-24 Nm
Battery capacity, cable length and cable
cross-section should be selected to match.
Engine models D2676 LE4XX

Starter type Mitsubishi Electric Corporation
Rated voltage V 24
Rated output kW 5.5
6.11.2 Alternator
Alternator for charging starter batteries

One alternator (1) respectively is available for
charging the starter batteries of each engine.
The alternator is completely wired in the factory.
This alternator may not be used to charge
batteries that supply additional consumers.
Generator for charging additional batteries
If, independently of this, batteries for supplying
other consumers are to be charged, a second
generator (2) (optional) can be fitted.
Engine types D2676 LE4XX

Alternator type Bosch
Rated voltage 28 V
Rated current 1 x 110 A or 2 x 120 A
Both generators are not two-pin insulated. In order

to achieve potential-free wiring, the entire
generator add-on on the engine is insulated. The
housing for the generators is therefore connected
to the negative terminal of the corresponding
battery.
Tightening torques for alternator in Nm

Mounting nut M8, terminal B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 + 2 Nm
6.11.3 Cover for the vibration damper (optional)
WARNING
Danger to life due to insufficient protective equipment
The cover included in the scope of supply (optional) is not protective equipment.
Therefore:
S Put suitable protective equipment in place before commissioning of the engine.
S Install touch protection, if not supplied cover for

vibration damper (1)
S Put in place suitable protective equipment.
The supplied cover (1) has a removable perforated
plate for power take-offs.
6.12 Connector plugs on engine
NOTICE
Risk of damage to components caused by incorrect handling
Therefore:
S For vibration decoupling, connecting cables must be attached to the engine or gearbox at a distance
of approx. 150 mm
Interfaces for:
X3 gearbox sensors
X30 commissioning sensors
X32 gearbox sensors
X33 gearbox oil pressure
X35 water level fuel pre filter
X61 exhaust aftertreatment system
X300 CAN-line exhaust aftertreatment system
(only for engines with DPF)
X968 engine / E-box
X990 engine / E-box (only classified engines)
In addition, for classified engines:
Voltage supply on fuse box

The power supply from the customer battery (1)
does not run via the starter, but it is fed directly to
the fuse box (3). Before that, the supresserdiode
(2) is installed.
Voltage supply EDC/AL-System
►X104.1
Voltage supply SU-System
►X104.6
6.13 Values of torque for screw connections according to the M 3059 works
standard
Screws / nuts with outer hex or inner hex threads, head without collar or flange
Thread size x Pitch Property classes / Tightening torque values in Nm

for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M4 2,5 4,0 4,5
M5 5,0 8,0 9,0
M6 9,0 13,0 15,0
M7 14,0 20,0 25,0
M8 22,0 30,0 35,0
M8x1 23,0 35,0 40,0
M10 45,0 65,0 75,0
M10x1,25 45,0 67,0 75,0
M10x1 50,0 70,0 85,0
M12 75,0 110,0 125,0
M12x1,5 75,0 115,0 130,0
M12x1,25 80,0 120,0 135,0
M14 115,0 175,0 200,0
M14x1,5 125,0 185,0 215,0
M16 180,0 265,0 310,0
M16x1,5 190,0 280,0 330,0
M18 260,0 365,0 430,0
M18x2 270,0 385,0 450,0
M18x1,5 290,0 405,0 480,0
M20 360,0 515,0 600,0
M20x2 380,0 540,0 630,0
M20x1,5 400,0 565,0 670,0
M22 490,0 700,0 820,0
M22x2 510,0 725,0 860,0
M22x1,5 540,0 750,0 900,0
M24 620,0 890,0 1040,0
M24x2 680,0 960,0 1130,0
M24x1,5 740,0 1030,0 1220,0
Screws / nuts with outer hex or inner hex threads, head with collar or flange
Thread size x Pitch Property classes / Tightening torque values in Nm

for 8.8 / 8 for 10.9 / 10 for 12.9 / 12
M5 6,0 9,0 9,9
M6 10,0 15,0 17,0
M8 24,0 35,0 41,0
M8x1 25,5 40,0 43,7
M10 44,5 65,0 75,9
M10x1,25 46,5 70,0 79,7
M10x1 48,6 75,0 83,5
M12 81,5 120,0 140,0
M12x1,5 85,0 125,0 146,0
M12x1,25 88,5 130,0 152,0
M14 128,0 190,0 221,0
M14x1,5 138,0 200,0 237,0
M16 200,0 285,0 334,0
M16x1,5 212,0 300,0 354,0
M18 279,0 395,0 464,0
M18x2 294,0 420,0 489,0
M18x1,5 309,0 440,0 515,0
M20 382,0 545,0 637,0
M20x2 400,0 570,0 667,0
M20x1,5 418,0 595,0 696,0
M22x2 558,0 795,0 930,0
M22x1,5 580,0 825,0 966,0
Installation torques for hollow screws and screw-in fittings, Screw plugs, hose fittings, and
screw-in fittings with cutting ring union
SPermitted for threaded connections with Cu and BS seal rings
SPermitted for threaded connections in aluminum female thread
SPermitted also for components with steel outside thread - materials according to DIN 3859-1
SImpact screws are not permitted for installation
SComponents that are much weaker when compared with standard parts must be evaluated separately
Applicable to: Applicable to:

-hollow screws (DIN 7643 or similar.) screw-in fittings (DIN 3901, MAN 200)
-screw-in fittings (DIN 3901/MAN 200 or similar for cutting ring union of a
or similar for cutting ring union of a continuing pipe line
continuing pipe line *)
-threaded plugs with inner and outer
hex (DIN 908, DIN 910/DIN 7604 or When tightening or loosening
similar.) the cutting ring union, the
-hose clamps and fittings for plug respective part cannot be held
connectors. in place.
Thread size
x pitch
M8X1 11 Nm 21 Nm
M10X1 21 Nm 32 Nm
M12X1.5 32 Nm 42 Nm
M14X1.5 42 Nm 70 Nm
M16x1.5 52 Nm 130 Nm
M18X1.5 65 Nm 130 Nm
M20X1.5 75 Nm 190 Nm
M22X1.5 85 Nm 190 Nm
M24X1.5 95 Nm 190 Nm
M26X1.5 105 Nm 190 Nm
M27X2 105 Nm ----
M28X1.5 105 Nm 262 Nm
M30X1.5 125 Nm ----
M32X1.5 125 Nm ----
M33X2 125 Nm ----
*) tighten the cutting ring union
Applicable to: Applicable to:

-hollow screws (DIN 7643 or similar.) screw-in fittings (DIN 3901, MAN 200)
-screw-in fittings (DIN 3901/MAN 200 or similar for cutting ring union of a
or similar for cutting ring union of a continuing pipe line
continuing pipe line *)
-threaded plugs with inner and outer
hex (DIN 908, DIN 910/DIN 7604 or When tightening or loosening
similar.) the cutting ring union, the
-hose clamps and fittings for plug respective part cannot be held
connectors. in place.
Thread size
x pitch
M36X1.5 157 Nm ----

M38X1.5 157 Nm ----
M42X1.5 190 Nm ----
M45X1.5 190 Nm ----
M48X1.5 190 Nm ----
*) tighten the cutting ring union
Tip for users

When tightening or loosening the cutting ring
union, the respective part can be held in place.
6.14 Initial start-up

The preparations for initial commissioning include the following:
S Thorough checking of the installation
S Fill with approved diesel fuel and vent the fuel system
S Fill with AdBlue®/DEF/AUS32
S Filling the engine with coolant, venting the cooling system
S Filling the engine (oil sump/oil filter) with the specified oil quantity
S Starting the engine
S Conducting a trial operation, measuring and archiving important data
The MAN diagnosis system MAN-cats® is required for commissioning.
NOTICE
Initial start-up that has not been carried out properly can result in operational faults that cause
irreparable damage to the engine
For this reason:
S Commissioning is carried out only by authorized personnel of MAN Nuremberg (Marine engines
department).
S The commissioning is performed using a commissioning record sheet.
DANGER
Risk of life from non-functional safety equipment and devices
For this reason:
S Before beginning work, check whether all safety equipment is functional and correctly installed.
S Prior to starting the engine, check whether all safety equipment is functional and correctly installed.
NOTICE
Risk of engine damage due to incorrect diesel fuel
JP8 diesel and biodiesel cause damage to the engine and aftertreatment system.
For this reason:
S Use only fuel which complies with the standards ASTM D975 or EN 590 as well as use of commercial
ULSD (specification of 15ppm max. sulfur fuel is required).
S In the event of damage, consult MAN or your MAN dealer for further direction.
S Additional information can be found in the MAN fluids recommendations.
For engines without exhaust aftertreatment system, commercial low sulfur diesel fuel (LSD) can also be
used.
Tip for users

Use only service products that meet MAN regulations; otherwise, the liability for material defects is
rendered void!
https://ws-public.man-mn.com/portal/irj/asp
6.14.1 Filling with AdBlue®/DEF/AUS32
HINWEIS
Risk of damage to property by cleaning agents or fuel
The engine and aftertreatment system are damaged.
For this reason:
S Do not use to dirty containers or funnels to fill/top up DEF/AdBlue®/AUS32.
S When filling/topping up DEF/AdBlue®/AUS32, only use refilling containers.
S If fuels gets into the DEF/AdBlue®/AUS32 tank, do not start the engine.
S Keep the DEF/AdBlue®/AUS32 tank and DEF/AdBlue®/AUS32 line system free of cleaning agents
and fuel.
Before initial start-up, fill the AdBlue®/DEF/AUS32 tank.
Risk of damage to the environment due to incorrect storage
Do not allow AdBlue®/DEF/AUS32 to escape into the waste water or soil.
For this reason:
S Storage temperature: max. 25 °C
S Absorb leaked or spilled AdBlue®/DEF/AUS32 using binding agent and dispose of it properly.
S Store AdBlue®/DEF/AUS32 only in the original containers.
Do not allow service products to escape into the waste water or soil.
For this reason:
S Do not spill any service products when filling.
6.14.2 Filling with diesel fuel
DANGER
Risk of fire from diesel fuel
For this reason:

S During refueling, do not smoke in the hazard zone.
S Using open flames and sources of ignition is forbidden in the hazard zone.
S Fill up the tank only when the engine in switched off.
S Pay attention to cleanliness.
S Do not spill any diesel fuel.
For this reason:
6.14.3 Bleeding the fuel system

Bleed the fuel system prior to initial start-up. This procedure is described in the maintenance instructions.
6.14.4 Filling with coolant
For this reason:
The engine cooling system should be filled with a mixture of potable water and antifreeze based on
ethylene glycol or anti-corrosion agent.
For coolant capacity, see chapter "Engine data".
S Add coolant in accordance with the information provided by the manufacturer of the overall system.
S Fill coolant slowly (max. 10 l/min).
6.14.5 Leakage check of the entire cooling system

Check the cooling system for leaks prior to initial start-up. This procedure is described in the maintenance
instructions.
Control and Operation
7 Control and Operation
7.1 Prerequisite
Before commencing work, read and adhere to the General Safety Instructions and the Safety Instructions
in this chapter
Follow the instructions unconditionally and proceed with care and attention, in order to avoid accidents and
injury to persons and damage to property.
Wear personal protective equipment

S Safety boots
S Safety gloves
Personnel
The engine should be controlled and operated only by instructed persons or by trained specialists.
Basic rules
WARNING
Danger due to incorrect operation
Improper operation leads to severe personal injuries or damage to property.
Therefore:
S Perform all operational steps in accordance with the information provided in this manual.
S Before beginning work, ensure that all covers and safety equipment are functional and have been
installed correctly.
7.3 Preparations prior to operation
NOTICE
Risk of engine damage from incorrect inspections
Therefore:
S Before each operation, perform a visual inspection and check the engine for damage or leaks.
S Do not operate the engine if it is damaged.
S Rectify minor faults immediately.
Tip for users

For more information, see the MAN service product database.
The basic requirement for trouble-free operation is to provide service products that have been approved
by MAN.
Check the fuel supply, coolant level and oil level prior to operation every time.
If required, top up diesel fuel, coolant, oil and AdBlue®/DEF/AUS32.
7.3.1 Check the fuel supply and top it up
DANGER
Risk of fire caused by Diesel fuel
Diesel fuel is easily inflammable.
Therefore:
S During operation, do not smoke in the hazard zone.
Prohibit working with exposed flames and sources of ignition.
S Fill up the tank only when the engine in switched off.
S Pay attention to cleanliness.
S Do not spill any diesel fuel.
Do not allow service products to escape into the soil, ponds, lakes and the like.
Therefore:
S Do not spill any service products when topping up.
1. Check the fuel supply and top it up, if required, according to the information provided by
the manufacturer of the complete system.
2. Open the shut-off valves in the fuel supply.
7.3.2 Checking DEF/AdBlue®/AUS32 and topping it up
Therefore:
Tip for users

Check the liquid level against the value specified by the manufacturer of the overall system and top up if
necessary.
7.3.3 Check the coolant level and top it up
CAUTION
Risk of scalding by hot service products
Therefore:
S Check the coolant level only when the engine has cooled down.
NOTICE
Risk of engine damage from improper antifreeze
Therefore:
S Use only appropriate antifreeze.
Therefore:
The engine cooling system should be filled with a mixture of potable water and antifreeze based on
Checking the coolant level
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.
Topping up the coolant
NOTICE
Risk of engine damage from temperature differences
Therefore:
S Do not fill cold coolant into a hot engine.
CAUTION
Risk of injury from hot liquids
The coolant reaches high temperatures during operation and causes scalding upon contact.
Therefore:
S Undo the cap cautiously with the safety valve.
S Release the pressure.
S Open the cover cautiously.
Use only service products that meet MAN regulations; otherwise, the liability for material defects is
rendered void!
Tip for users

Top up the coolant level only when the engine

has cooled down.
► If, under exceptional circumstances the
coolant level needs to be checked when the
engine is at operating temperature, turn the
cap (1) carefully to the pre-latching position -
relieve the pressure - and then open it carefully.
► Do not fill in any cold coolant in an engine at
operating temperature while topping up.
► Make sure that the “water - antifreeze” mixing
ratio is restored.
► The engine cooling system should be filled with
a mixture of tap water and antifreeze based on
► Screw on the cap (1) hand-tight.
Caps that have been tightened forcefully can
no longer be opened!
If the cooling system is opened when the engine is

at operating temperature, then the pressure drops
in the cooling system.
As a result, subsequent operation of the engine
may trigger the alarm “Pressure in the expansion
tank” in the MMDS.
In order to be able to continue operating the
engine after opening the cover without the alarm,
system pressure of min. 0,5 bar must be present in
the cooling system.
In order to achieve this, a pressure valve (1) is
installed on the expansion tank to which a
commercially available air pump may be
connected. The pressure in the expansion tank
must be raised to 1 bar with this pump.
7.3.4 Check the engine oil level

Information about unmarked oil dipstick, see installation instructions.
Tip for users

Check the oil level when the engine is in a horizontal position and only about 5 minutes after it has been
shut down.
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 with a lint-free clean
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.
Between the markings (min/max) are 6-liter oil fill
capacity.
Oil dipstick right
MAX
MIN
7.3.5 Topping up the engine oil
Do not allow service products to escape into the soil, ponds, lakes and the like.
Therefore:
S Do not spill any service products when topping up.
NOTICE
Risk of engine damage from incorrect
oil level
Therefore:
S Never fill in more than the quantity of oil
specified.
S Pay attention to the Min/Max marking on MAX
the oil dipstick.
S Check the oil level and correct if necessary. MIN
► 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.
For oil capacity, see chapter “Engine data”.
► Screw the cap (1) back on.
► Check the engine oil level.
Between the markings (min/max) are 6-liter oil fill
capacity.
7.3.6 Drain the separated water of the fuel pre-filter

To protect the engine from dirt and water in the fuel, a fuel pre-filter with water separator is installed
in the fuel line from the tank to the engine.
NOTICE
Risk of engine damage from water and dirt in the fuel
Therefore:
S Depending on the incidence of water, service the fuel pre-filter regularly according to the
manufacturer's specifications.
Drain the water from the fuel pre-filter
► Remove protective plate (classified engines).

► Disconnecting the electrical connections.
► Open the drain plugs (1),
- as required
- if monitoring system alarm appears
- during each engine oil change
► Allow the collected water to drain off into
a suitable container.
► Close the drain plugs (1).
► Install protective plate (classified engines).
(classified engines)
(non classified engines)
7.3.7 Changing over the fuel pre-filter/fuel filter

Selectable filters are a requirement of the classification agencies.
Switch levers are only available in the classified version.
Lever position:
1. Both Filter in use (operating position)
2. Left Filter in use
3. Right Filter in use
Position 2 or 3 is permitted only at idle
7.3.8 Selector lever - oil filter

Selectable filters are a requirement of the classification agencies.
Switch levers are only available in the classified version.
HINWEIS
Component damage due incorrect oil
supply
Deshalb:
S Do not leave the changeover lever in any in
termediate position
Lever position:
1. Both filter in use (operating use)
2. Filter off, right side
3. Filter off, left side
Position 2 or 3 is permitted only at idle
7.3.9 Daily inspection before starting the engine

Visual inspections and functional checks to be done daily:
S Oil leakages
S Fuel leakages
S Coolant leakages
S Condition of the ribbed V-belt
S Loose or defective parts, loose screw connections
S Check level of supplies
When the engine is running:
S Unusual noises
S Smoke development
7.4 Operate the engine in driving mode
7.4.1 Operating ranges for marine engines

Relative load of MMDS %
Speed in %
(1) Full load curve of the engine
Operating range
(2) Acceleration
S Short-time operation to increase the load by raising the speed
S Speed less than 100 % of the nominal engine speed
S Continuous operation for “heavy” mode is permissible
S Continuous operation for operating modes “moderate” and “light” is not permissible
(3) Normal operation
S Continuous operation is permissible, final speed 100 to 102 % of the nominal engine speed
(4) New condition
S Operating range for a new and fully loaded ship
S Continuous operation is permissible, final speed 102 to 104 % of the nominal engine speed
(5) Light load
S Operating range with relatively high speeds and low loads
S Continuous operation is permissible, but it is inefficient
Maintenance and care
8 Maintenance and care
8.1 Maintenance Manual
NOTICE
Risk of engine damage due to improper maintenance
For this reason:

S Before carrying out maintenance work, read the maintenance manual carefully.
S Carry out all maintenance work in accordance with the information in the associated documentation.
S Observe the service intervals.
S All components of the engine surroundings are to be included in the maintenance.
S Ensure adequate room for assembly before beginning the work.
Maintenance Manual
In addition to these operating instructions, there is a maintenance manual available for performing
maintenance on engines.
It contains a maintenance schedule and a description of maintenance work that is due at regular intervals.
Aftertreatment system maintenance instructions

In addition to these operating instructions, there is a maintenance instructions available for the modular
aftertreatment system for the maintenance of the aftertreatment system.
It contains a maintenance schedule and a description of maintenance work that is due at regular intervals.
Maintenance schedule
The maintenance schedule contains all maintenance work that needs to be done at regular intervals of time
or on reaching a certain number of operating hours.
Maintenance work
The maintenance manual contains a brief description of the maintenance work.
8.2 Repair Manual

The repair manual contains a detailed description of all assembly and adjustment work on the engine.
This work should be done only by specialists who have been trained particularly for repair.
Faults
9 Faults
The engines are equipped with an intelligent marine monitoring system.
See Operating Instructions „MAN Intelligent Marine Safeguard System“
All important engine parameters are continuously recorded by sensors. This data is captured by the MAN
Monitoring and Diagnostic system and compared with stored target values.
In the event of a fault, the recorded engine parameters lie outside the permitted tolerance ranges and the
system initiates an alarm.
The MAN Monitoring and Diagnostic system can reduce the power output of the engine being monitored to
prevent consequential damage.
The MAN Monitoring an Diagnostic system can stop the monitored engine independently if the operation of
the machine is endangered by a technical defect.
To ensure the safety of the ship in hazardous circumstances, the override-system offers the possibility to
prevent the shutdown of the engine or the reduction of output, and to reactivate the full engine output.
Registered alarms are highlighted both visually and acoustically:
S On the color touch display at the operator´s stand and engine control room
S On the terminal box display (E-Box) in the engine room
NOTICE
Risk of engine damage
Alarms indicate technical faults which can result in consequential damage
For this reason:
S Arrange for the cause of a fault to be rectified immediately by MAN Service for marine engines.
A current directory of the service support locations can be found on the Internet at:
http://www.asp.mantruckandbus.com

Decommissioning and recommissioning
10 Decommissioning and recommissioning
10.1 Requirements
Before starting the work, read and follow the general safety instructions and the safety instructions given in
this chapter.
Follow the instructions in all cases and proceed with care in order to prevent accidents, personal injury and
material damage.

S Safety shoes
S Safety gloves
Personnel
Only instructed technical professionals should decommission or recommission an engine.
Basic rules
WARNING
Risk of injury caused by untrained personnel
For this reason:
S Carry out all work steps in accordance with the information in these instructions.
S Have the engine serviced and repaired only by trained personnel.
S Regular attendance at product and user training.

10.3 Taking the engine out of operation temporarily

Depending on the duration, temporary corrosion protection that meets MAN factory standard M 3069 is
required when taking an engine out of operation.
The factory standard is available from the customer service department at the Nuremberg factory.
Tip for users

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 endeavor to preserve engines at the time of shutting them down or, in the case of
new engines, after the factory test run.
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, rainwater and the like that have entered sometimes require complete disassembly
of the engine.
10.3.1 Taking the engine out of operation for up to 3 months

Even simple measures prior to temporary shut-down of the engine provide effective protection against
corrosion:
S Clean the outside of the engine thoroughly with compressed air. Dry the engine surface.
S Fill the fuel tank with diesel fuel.
S For information on establishing the concentration of the antifreeze in the coolant and the prescribed
mixing ratio, refer to the publication "Service products for MAN industrial and marine diesel 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.
10.3.2 Taking the engine out of operation for 3 to 6 months

If the engine is shut down for more than 3 months, engine preservation is necessary in addition to the
measures mentioned in 10.3.1.
10.3.2.1 Fuel system preservation

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 fuel and 2 vol. % anti-corrosion
agent, see MAN factory standard M3069.
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 Operate the engine that has warmed up with anti-corrosion fuel for 3 minutes at nominal speed.
S Operate the engine for 2 minutes at idling speed.
S Switch off the engine.
S Close the openings for intake air and exhaust gas air-tight until the engine is still hot.
10.3.2.2 Preserving the intake and exhaust gas system

S Spray corrosion protection oil (see MAN factory standard M3249, 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.

10.4 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 endeavor to preserve engines at the
time of shutting them down. When doing so, the regulations specified in the MAN works standard M3069
must be observed.
Tip for users

The engines are provided ex-factory with preservation according to the M3069 factory standard.
The factory standard is available from the customer service department at the Nuremberg factory.
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:
10.4.1 Putting preserved engines into operation according to the M 3069 MAN
factory standard
1. Remove external preservation and do not use a high-pressure cleaner under any circumstances.
2. Remove the cap from the intake and exhaust gas outlet.
3. Check the cooling system, fill with antifreeze according to the service products list (see the "Service
products ..." publication for this purpose), check the concentration and correct it if required.
4. Check the engine oil level, and fill with fresh approved engine oil if required.
5. Add fuel, bleed the system.
Check the function of the monitoring and emergency shut-down equipment.
6. Check elastic connecting elements such as V-belt, coolant and charge air hoses for their condition, and
check for proper assembly or correct tensioning.
7. 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.
8. Allow filling and start the engine.
9. Check the engine for leakage points, check for abnormal noise development and observe the oil
pressure and temperature. Start up the engine by increasing the load in steps.
10.After maximum 25 hours of operation, drain preservation oil from the engine and replace the oil filter,
then refill with fresh approved engine oil.
Tip for users

You can find approved products on the Internet at:

10.4.2 Commissioning of unpreserved engines

In addition to the steps for a preserved engine, commissioning unpreserved engines requires the following
additional work, depending on potential damage caused during standstill.
1. Perform endoscopy on the combustion chambers and disassemble and install injectors for this purpose.
Check the valves for free movement, check the valve clearance and adjust it if required.
Replace damaged / corroded parts.
2. Drain used engine oil from the engine and replace the oil filter, then refill with fresh approved engine oil.
3. 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, remove and install the
coolant pump and thermostats, replace the axial face seal of the coolant pump and the thermostat
inserts, and test the cooling system under pressure.
4. Check the clean air system, air filter and exhaust gas turbocharger for dirt or impurities, and clean or
repair them if required.
5. Clean the fuel system and drain the old fuel if necessary. Check the filter, and clean or replace it, if
necessary.
10.5 Decommissioning and recommissioning of the DEF/AdBlue®/AUS32 system

For information, see "Modular aftertreatment system" maintenance instructions.

Technical data
11 Technical data
11.1 Weight specifications

Ensure that suitable hoisting gear is used for handling the engine and the engine parts listed in the table.
Name Weight (kg)

Oil pan 44
Crankcase 260
Cylinder head 138
Crankshaft 104
Flywheel (standard / heavy) 55 / 92
Charge air cooler 48
Exhaust pipe 45
Expansion tank 33
Flywheel housing 45
Vibration damper 34
Exhaust turbocharger 26
Engine carriage 125
Technical data
11.2 Dimensions and weights
Specification D2676 LE3XX Unit

Engine weight, dry
appr. 1251 kg
(depending on the scope of supply)
A 1795 mm
B 986 mm
C 1096 mm
11.3 Requirements of the installation site and space requirement

Observe the information in the installation instructions.
Technical data
11.4 Engine specifications - Light-duty operation
11.4.1 D2676 LE426 / LE456

Emission level IMO Tier II / US Tier 3
Design in line, vertical
Principle of operation 4-stroke diesel
Combustion process Direct injection
Turbocharging 1-stage exhaust gas turbocharging with charge air cooling and charge air
control (Waste Gate)
Number of cylinders 6
Cylinder bore 126 mm
Piston stroke 166 mm
Cylinder capacity 12 419 cm3
Compression ratio 16,5 : 1
Operating mode Up to 500 operating hours per year, ≤ 5 % time full load,
Power
D2676 LE426 588 kW / 800 HP at 2300 rpm
D2676 LE456 625 kW / 850 HP at 2300 rpm
Max. torque
D2676 LE426 2685 Nm at 1300 - 2100 rpm
D2676 LE456 2740 Nm at 1400 - 2100 rpm
Firing order DIN 73021 1-5-3-6-2-4
Valve clearance, with cold engine
Inlet valve 0.50 mm
Exhaust valve 0.80 mm
Fuel system
High pressure pump Bosch CP 3.4
Injection system Common Rail
Controller Electronically controlled diesel injection
(EDC) - Type EDC 17
Injectors 8-hole nozzles

Engine lubrication Force-feed lubrication
Oil change quantity (with filter) 40 l or 60 l with flat oil pan
Oil filter Oil module with oil cooler and oil separator
Engine cooling Liquid cooling
Coolant filling quantity 55 l
Coolant temperature 80 - 90 °C, for a short time 95 °C is permissible
Electrical equipment
Starter 24 V; 5.5 kW
Three-phase alternator 28 V; 1 x 110 A or 2 x 120 A
Technical data
11.5 Engine specifications - Medium-duty operation
11.5.1 D2676 LE428 / LE438

Emission level IMO Tier III
Compression ratio 18 : 1
Operating mode Up to 3000 operating hours per year, max. 50 % time full load, mean utili
sation max. 70 %
Power
D2676 LE428 441 kW / 600 HP at 2100 rpm
D2676 LE438 412 kW / 560 HP at 2100 rpm
Max. torque
D2676 LE428 2214 Nm at 1400 - 1900 rpm
D2676 LE438 2075 Nm at 1300 - 1900 rpm
Inlet valve 0.50 mm
Fuel system
(EDC) - Type EDC 17

Three-phase alternator 28 V; 1 x 110 A or 2 x 120 A
Technical data
11.6 Engine specifications - Heavy-duty operation
11.6.1 D2676 LE477 / LE487 / LE497

Emission level IMO Tier III / EU Stage V
Compression ratio 18 : 1
Operating mode unlimited
Power
D2676 LE477 368 kW / 500 HP at 1800 rpm
D2676 LE487 290 kW / 394 HP at 1800 rpm
D2676 LE497 331 kW / 450 HP at 1800 rpm
Max. torque
D2676 LE477 2185 Nm at 1200 - 1600 rpm
D2676 LE487 1760 Nm at 1300 - 1600 rpm
D2676 LE497 1980 Nm at 1200 - 1600 rpm
Inlet valve 0.50 mm
Fuel system
(EDC) - Type EDC 17

Three-phase alternator 28 V; 110 A or 2 x 120 A
Technical data
Installation drawings
12 Installation drawing
Installation drawings
Indexes
13 Indexes
Indexes
13.1 Abbreviations
A . . . . . . . . . Ampere MAX . . . . . . Maximum

Ah . . . . . . . . Ampere hours min . . . . . . . Minutes
Any . . . . . . . Possibly MIN . . . . . . Minimum
approx. . . . Approximately mm . . . . . . . Millimetre
ATL . . . . . . Exhaust gas turbocharger Nm . . . . . . . Newton-metre
C . . . . . . . . . Celsius or . . . . . . . . and / or
CAN . . . . . . Network for control devices and data perm. . . . . . permissible
bus systems in the vehicle (Controller
rpm . . . . . . . Revolutions per minute
Area Network)
UD . . . . . . . Upper dead centre
cm3 . . . . . . . . Cubic centimetre
UBat ....... Battery voltage
Co. . . . . . . . Company
V . . . . . . . . . Volt
CR . . . . . . . Common Rail
W . . . . . . . . Watt
EDC . . . . . . Electronically controlled diesel
injection (Electronic Diesel Control) > . . . . . . . . . greater than
e.g. . . . . . . . For example < . . . . . . . . . less than
etc. . . . . . . . and so on (etcetra)
ggf. . . . . . . . If required or applicable
h . . . . . . . . . Hour
kg . . . . . . . . Kilogram
Kl. . . . . . . . . Terminal
kW . . . . . . . Kilowatt
LCD . . . . . . Liquid Crystal Display
LD . . . . . . . Lower dead centre
LED . . . . . . Light Emitting Diode
m . . . . . . . . Metre
Indexes
13.2 Technical terms
EDC, Electronic Diesel Control, is an electronically

controlled diesel injection system. It affects the fuel
consumption, the efficiency, the exhaust gas and
noise behaviour favourably.
DEF/AdBlue ®/AUS32 is a pure, clear, syntheti

cally manufactured 32,5 % urea-water solution.
This involves a urea solution being injected into the
exhaust stream, which triggers a chemical reaction
in the SCR catalyst.
SCR, selective catalytic reduction describes the

technology of reduction of nitrogen oxides (NO,
NOx) in the exhaust gas of internal combustion
engines. In the process, ammonia (NH3) is mixed
into the exhaust gas. A reaction takes place in a
catalytic converter. The products of this reaction
are water (H2O) and nitrogen (N2).
Indexes
13.3 Keyword Index
A E
Aftertreatment system maintenance Engine type plate, 27
instructions, 87 Engine views, 32
Alarms, initiating, 88 Environmental protection, 25
Alternator, 66 Exhaust system, Exhaust gas outlet at the
Attaching the cooling system, 50 engine, 61
Explanation of icons, 9
B
Bleeding the fuel system, 74 F
Body and function, 30 Faults, 88
Fill with fuel, 74
C Filling with coolant, 75
Check the fuel supply and top it up, 77 Flywheel, 31
Checking AdBlue® level and topping it up, 78 Flywheel housing, 31
Classification, General, 31 Fuel filter, changing over, 84
Conduct in the event of a hazard, 23 Fuel pre-filter, Drain the water, 83
Connecting the fuel lines, 54 Fuel system, Description, 30
Content of these instructions, 14
Control and Operation, 76 H
Coolant, Topping up, 78 Hull cooling, Connections on the engine, 52
Coolant level, check, 78 Hydraulic pumps, 64
Cooling system, 30
Copyright protection, 10 I
Customer service, 12 Information about these instructions, 7
Injection system, 30
D Installation - Engine, 44
Decommissioning and recommissioning, 89 Installation and Commissioning, 43
Description of engine, 30 Intake and exhaust system, 31
Dimensions and weight, 94
Disposal, 11 L
Limitation on liability, 10
E
Elastic mounts, Flange-mounted V-gearbox, 49 M
Electrical system, 65 Maintenance and care, 87
Emission label, 28 Maintenance Manual, 87
Engine foundation, 49 Maintenance schedule, 87
Engine lubrication, 30 Maintenance work, 87
Engine oil Modifications and conversions, 14
Check the engine oil level, 81
Topping up the engine oil, 82
Engine specifications
Heavy-duty operation, 97
Light-duty operation, 95
Medium-duty operation, 96
Indexes
O T
Oil filter, Selector lever, 85 Taking out of operation temporarily, 90
Operating ranges, 86 Technical data, 93
Other applicable documents, 10 Transport, 39
Transport inspection, 38
P Transport, packing and storing, 36
Packaging, 38
Personal protective equipment, 16 W
Plugs on engine, 68 Warranty provisions, 12
Power take-off, 64 Weights, 93
Preface, 7
Preparations prior to operation, 77
Proper use, 13
Protective devices, 22
R
Repair Manual, 87
Requirements of personnel, 15
Requirements of the installation site and space
requirement, 94
Responsibility of the operating company, 14
Restarting engines that have been shut down, 91
S
Safety equipment, 22
Service support locations, 88
Signage, 24
Spare parts, 11
Special hazards, 17
Start-up, Preparations, 73
Starter, 65
Storage, 38

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Operating Instruction

MAN Marine Diesel Engines

51.99587-5041 “Translation of the original instruction”

MAN Truck & Bus SE

Technical status as on: 02/2020

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

3 Engine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Body and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5 Transport, packing and storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7 Control and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

10 Decommissioning and recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Engine types Output in kW Nominal speed Emission level Aftertreatment system

1.1 Information about these instructions

Read these instructions carefully before starting any work!

1.1.1 Supplementary publications to these instructions

1.1.2 Other publications

Read these instructions carefully before starting any work!

1.2 Explanation of icons

Tips and Recommendations

Tip for users

Read these instructions carefully before starting any work!

1.3 Limitation on liability

1.4 Copyright protection

Tip for users

1.5 Other applicable documents

Read these instructions carefully before starting any work!

1.6 Spare parts

Tip for users

Order spare parts from an authorized dealer or directly from MAN.

Read these instructions carefully before starting any work!

1.8 Warranty provisions

1.9 Customer service

Tip for users

Read these instructions carefully before starting any work!

2 General safety instructions

2.1 Proper use

Read these instructions carefully before starting any work!

2.2 Content of these instructions

2.3 Modifications and conversions to the engine

2.4 Responsibility of the operating company

Read these instructions carefully before starting any work!

2.5 Requirements of personnel

Tip for users

2.5.2 Unauthorized persons

Read these instructions carefully before starting any work!

2.6 Personal protective equipment

Industrial protective clothing

Clothing for special work

Read these instructions carefully before starting any work!

2.7 Special hazards

For this reason:

For this reason:

Flying parts in the event of sudden engine damage

Read these instructions carefully before starting any work!

For this reason:

Easily inflammable materials - diesel fuel, oils and greases

Coolants - antifreeze and anti-corrosion agent