D 2848 LE 401 / 403 / 405

D 2840 LE 401 / 402 / 407

D 2842 LE 401 / 402 / 403 / 406 / 408 / 411 / 412 / 413

Preface

Dear Customer,
these Operating Instructions are intended to familiarize you with your new MAN Diesel
engine and how it operates.
This manual contains information on Fuels, Lubricants and Coolants for MAN Diesel Engines.
This manual is supplemented by the publication Service record book.
Note:
All three publications belong to the engine and must always be kept ready to
hand near the engine in the engine room.
Comply in full with instructions relating to operation, prevention of accidents and
environmental protection.
MAN Diesel engines are developed and manufactured in line with the latest state of the
art. However, trouble-free operation and high performance can only be achieved if the
specified maintenance intervals are observed and only approved fuels, lubricants and
coolants are used.
Note:
Only use fuel, coolants and lubricants in accordance with MANs regulations
otherwise the manufacturers warranty will not apply!
For basic information on the fuels see the publication Fuels, Lubricants and
Coolants for MAN Diesel Engines.
You can find the approved products in the internet under:
http://www.man-mn.com/ " Products & Solutions " E-Business
It is imperative and in your own interest to entrust your MAN Local Service Centre with
the removal of any disturbances and with the performance of checking, setting, and
repair work.

Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Werk Nrnberg

Subject to change to keep abreast with technological progress.

2006 MAN Nutzfahrzeuge Aktiengesellschaft

No parts of this publication may be reproduced or translated without prior written permission of MAN. MAN explicitly reserves all rights according to copyright law.
MTDB

Technical status: 03.2006

5

51.994938498

Instructions
Important instructions which concern technical safety and protection of persons are emphasised as shown below.
Danger:
This refers to working and operating procedures which must be complied with in
order to rule out the risk to persons.
Caution:
This refers to working and operating procedures which must be complied with in
order to prevent damage to or destruction of material.
Note:
Explanations useful for understanding the working or operating procedure to be
performed.

Fitting flat seals / gaskets

Flat seals / gaskets are often inserted with sealing agents or adhesives to make fitting
them easier or to achieve better sealing. Flat seals may slip in operation due to the sewing-machine effect, in particular if they are used between parts with different rates of linear expansion under heat (e.g. aluminium and cast iron), and leaks may then occur.
Example:
the cap of the front crankshaft seal. If a sealing agent or an adhesive is used here the flat
seal will move inwards in the course of time as a result of the different expansion rates of
the materials. Oil will be lost, for which the shaft seal may be thought to be responsible.

Flat seals / gaskets can be fitted properly only if the following points are observed:
D Use only genuine MAN seals / gaskets
D The sealing faces must be undamaged and clean
D Do not use any sealing agent or adhesive as an aid to fitting the seals a little grease
can be used if necessary so that the seal will stick to the part to be fitted
D Tighten bolts evenly to the specified torque

Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Engine views D 2842 LE 401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation monitoring system BE1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16
18
20
21
22
44

Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary decommissioning of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45
48
51
54
55
55

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

Declaration

Declaration
In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of
Directive 89/392/EEC, version 93/44/EEC

MAN Nutzfahrzeuge Aktiengesellschaft,

hereby declares that the engine described below is destined for installation in a machine
as defined in the EC directive on machines.
Engine model:
Design:
Engine number:

For data see original declaration

If required this declaration is
enclosed with the delivery note.

Rating / speed:
Note:
The manufacturer of the complete ready-to-use machine in which this engine is
to be installed must take the further action necessary in the context of indirect
safety-related engineering and provision of instructions to ensure that the readyto-use machine complies with the requirements of the EC directive on machines.
The engine must not be put into operation until the complete machine satisfies
the conditions laid down in the EC directive on machines 89/392/EEC, most
recently amended by 93/44/EEC, or the latest amendment of said directive.

MAN Nutzfahrzeuge Aktiengesellschaft

Vogelweiherstrae 33
D90441 Nrnberg

Declaration

Nameplates
In all your correspondence please always
quote engine model, serial number and job
number (Order number).
For this reason it is advisable to read off the
data from the engine type plates before
putting the engine into operation and to
enter them in the appropriate spaces.
The engine type plates are on the crankcase (see illustration).
Model
MAN Nutzfahrzeuge Aktiengesellschaft
Typ
Motor-Nr. / Engine No.

......................................................................
delivered on

NI/II

......................................................................
installed on
......................................................................
Engine serial number
......................................................................
Order number
......................................................................

MAN Nutzfahrzeuge Aktiengesellschaft

Aktiengesellsc
Werk Nrnberg Germany

Bauj. Year Typ

Speed rpm

Leistg. PS Rating BHP Aufstellhohe m uNN Altitude m

:

Temp.C

Serial No

Job No Leistung kW Rating kW Drehz. 1/min

WerkNr.

Model MotorNr.

0219

10

Safety regulations

General notes
Day-to-day use of power engines and the service products (fuels, lubricants, coolants) necessary for running them presents no problems if the persons occupied
with their operation, maintenance and care are given suitable training and think as
they work.
This summary is a compilation of the most important regulations. These are broken down
into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution. In addition to these regulations those dictated by
the type of engine and its site are to be observed also.
Important:
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the
eyes etc., consult a doctor immediately.

1. Regulations designed to prevent accidents with injury to persons

During commissioning, starting and operation
D Before putting the engine into operation for the first time, read the operating instructions carefully and familiarize yourself with the critical
points. If you are unsure, ask your MAN representative.
D For reasons of safety we recommend you attach a notice to the door of
the engine room prohibiting the access of unauthorized persons and that
you draw the attention of the operating personal to the fact that they are
responsible for the safety of persons who enter the engine room.
D The engine must be started and operated only by authorized personnel.
Ensure that the engine cannot be started by unauthorized persons.
D When the engine is running, do not get too close to the rotating parts.
Wear close-fitting clothing.

D Do not touch the engine with bare hands when it is warm from operation
risk of burns.

D For safety reasons a separate, functioning red emergency-stopbutton for each engine must be installed at every bridge (the engine
must stop immediately when the button is pressed once).
11

Safety regulations
D Exhaust gases are toxic. Comply with the instructions for the installation
of MAN Diesel engines which are to be operated in enclosed spaces.
Ensure that there is adequate ventilation and air extraction.
D Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
During maintenance and care
D Always carry out maintenance work when the engine is switched off.
If the engine has to be maintained while it is running, e.g. changing the
elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts.
D Change the oil when the engines is warm from operation.
Caution:
There is a risk of burns and scalding. Do not touch oil drain plugs or oil
filters with bare hands.
D Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the oil will not overflow.
D Open the coolant circuit only when the engine has cooled down.
If opening while the engine is still warm is unavoidable, comply with the
instructions in the chapter entitled Maintenance and Care.
D Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional hydraulic oil circuit) during the operation.
The fluids which flow out can cause injury.
D Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The
tank must be filled only when the engine is switched off.

D When using compressed air, e.g. for cleaning the radiator, wear goggles.

D Keep service products (anti-freeze) only in containers which can not be

confused with drinks containers.

12

Safety regulations

D Comply with the manufacturers instructions when handling batteries.

Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.

2. Regulations designed to prevent damage to engine and premature wear

Do not demand more from the engine than it is able to supply in its intended application.
Detailed information on this can be found in the sales literature. The injection pump must
not be adjusted without prior written permission of MAN Nrnberg.
If faults occur, find the cause immediately and have it eliminated in order to prevent more
serious damage.
Use only genuine MAN spare parts. MAN will accept no responsibility for damage resulting from the installation of other parts which are supposedly just as good.
In addition to the above, note the following points:
D Never let the engine run when dry, i.e. without lube oil or coolant.
D When starting do not use any additional starting aids (e.g. injection with starting pilot).
D Use only MAN-approved service products (fuel, engine oil, anti-freeze and anti-corrosion agent). Pay attention to cleanliness. The Diesel fuel must be free of water. See
Maintenance and care.
D Have the engine maintained at the specified intervals.
D Do not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
D Never put cold coolant into an overheated engine. See Maintenance and care.
D Do not add so much engine oil that the oil level rises above the max. marking on
the dipstick. Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered to.
D Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, coolant temperature) function satisfactorily.
D Comply with instructions for operation of the alternator. See Maintenance and care.
D Do not let the raw water pump run dry. If there is a risk of frost, drain the pump when
the engine is switched off.

13

Safety regulations

3. Regulations designed to prevent pollution

Engine oil and filter elements / cartridges, fuel / fuel filter
D Take old oil only to an old oil collection point.
D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the
ground.
The drinking water supply could be contaminated.
D Filter elements are classed as dangerous waste and must be treated as such.
Coolant
D Treat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.
D When disposing of spent coolant comply with the regulations of the relevant local authorities.

4. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil decreases the
skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal experiments. If the basic rules of hygiene and health and safety at work are observed, health
risks are not to the expected as a result of handling used engine oil.
Health precautions:
D Avoid prolonged or repeated skin contact with used engine oil.
D Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
D Clean skin which has been in contact with engine oil.
Wash thoroughly with soap and water. A nailbrush is an effective aid.
Certain products make it easier to clean your hands.
Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
D After washing apply a fatty skin cream to the skin.
D Change oil-soaked clothing and shoes.
D Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly
Engine oil can endanger the water supply

14

Safety regulations
For this reason do not let engine oil get into the ground, waterways, the drains or the
sewers. Violations are punishable.
Collect and dispose of used engine oil carefully. For information on collection points
please contact the seller, the supplier or the local authorities.
Adapted from Notes on handling used engine oil.

15

Commissioning and operation

Engine views D 2842 LE 401
1

8
13

10

11

12

14

15

19

18 17

16

16

Commissioning and operation

1 Heat exchanger and coolant surge tank
2 Coolant filler neck
3 Intercooler
4 Relief valve on coolant surge tank
5 Oil filler neck
6 Air intake
7 Water pump (engine coolant circuit)
8 Oil drain plug
9 Oil dipstick
10 Starter motor
11 Exhaust pipe, liquid-cooled
12 Waste Gate
13 Turbocharger, liquid-cooled
14 Oil separator valve for crankcase breather
15 Engine cranking device
16 Oil sump
17 Oil cooler
18 Connection for oil pressure sensor
19 Oil filter

17

Commissioning and operation

First commissioning
When putting a new or overhauled engine into operation for the first time pay attention to
the Installation instructions for MAN marine diesel engines without fail.
It is recommended that new or overhauled engines should not be operated at a load
higher than about 75% maximum load during the first few hours of operation. Initial run-in
should be at varying speeds. After this initial run-in, the engine should be brought up to
full output gradually.
Note:
Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc.).
Otherwise the manufacturers warranty will become null and void.

Filling with fuel

Caution:
Fill the tank only when the engine is switched off. Pay attention to cleanliness.
Do not spill fuel.
Use only approved fuels (see Fuels, Lubricants etc.)
Caution:
Fill the tank only when the engine is switched off. Pay attention to cleanliness.
Do not spill fuel.
Use only approved fuels (see Fuels, Lubricants etc.)

Filling-in of coolant
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze
agent on ethylene glycole basis or anti-corrosion agent.
See Publication Fuels, Lubricants and Coolants for MAN Diesel Engines.
D Pour in coolant slowly via expansion tank, see page 52
D For coolant filling quantity, see Technical data

18

Commissioning and operation

Raw water pump
Do not let raw water pump run dry.
Make sure that all valves / cocks in the
raw water circuit are open.
If there is a risk of frost, drain the raw water pump.

Filling with engine oil

Caution:
Do not add so much engine oil
that the oil level rises above the
max. marking on the dipstick.
Overfilling will result in damage to
the engine.

Oil

The engines are as a rule supplied without oil.

Pour oil into engine via filler neck (arrow),
see page 46.
For the quantity required see Technical
Data.

19

Commissioning and operation

Commissioning
Before daily starting the engine, check fuel level, coolant level and engine oil level and
replenish, if necessary.
Caution:
Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc.).
Otherwise the manufacturers warranty will become null and void.
Checking oil level
Check engine oil level only approx.
20 minutes after the unit has been
switched off.
D Pull out dipstick (arrow)
D wipe it with a clean, lintfree cloth
D and push it in again up to the stop
D Pull out dipstick again

Oil

The oil level should be between the two

notches in the dipstick and must never fall
below the lower notch. Top up oil as necessary.
Caution:
Do not add so much engine oil
that the oil level rises above the
max. marking on the dipstick.
Overfilling will result in damage to
the engine.

MAX
MIN

Ensure outmost cleanliness when handling fuels, lubricants and coolants.

20

Commissioning and operation

Starting
Danger:
Before starting make sure that no-one is in the engines danger area.
Ensure that the gearbox is in neutral.
Caution:
When starting do not use any additional starting aids (e.g. injection with starting
pilot).
Insert starter key and turn it to position I. The check lamp comes on to show that the
engine is ready for operation.
Turn starter key further to position II (pre-glow). The display lamp (usually in the drivers
station) comes on.
After the pre-glow period the display lamp begins to flash. This signalizes that the engine
is ready for starting.
Note:
If the engine is not equipped with a pre-glowing function, immediately turn the
starter key through to position III.
Turn key further up to the stop (position III). The display lamp goes out. The starter motor is actuated.
Lube oil pressure must build up at the oil pressure gauge. If it does not, switch off the engine immediately.
For cold engines (<20C) move control lever into starting position (against stop for maximum engine speed).
Note:
When starting the cold engine (control lever in starting position) retract the control
lever as quickly as possible into lower idling position after the engine has
started.
The warm engine can also be started with the control lever in idling position.
Do not operate starter for longer than 10 seconds at a time.
After ignition of the engine, release the starter button and adjust control lever for desired
speed.
If engine fails to start, release the key, wait about 30 seconds, then operate starter again.

21

Commissioning and operation

For repeated starting turn the key back to OFF.
If the engine is kept idling for long periods it may cool down and thus start to emit white
or blue smoke.
We therefore recommend that you do not let the engine idle for more than 5 minutes.
It is well known that with any internal combustion engine wear is higher during idling.
Idling for longer periods is also an environmental nuisance.
Caution:
Do not overload the engine. Do not exceed the maximum permissible engine tilt.
If faults occur, find their cause immediately and have them eliminated in order to
prevent more serious damage!
Display panel in the engine room. Functions independently of the BE1 operation
monitor and shows analog operating values from the engine.
During operation the oil pressure in the
engine lubrication system must be monitored. If the monitoring devices register a
drop in the lube oil pressure, switch off the
engine immediately.

Operation monitoring system BE1

Caution:
If an engine / gear box alarm is displayed on the monitoring device, the engine is
to be turned off, i.e. operated at low-pressure at a max. of 1200 rpm.
When following alarms are activated
engine oil pressure / reduction of lubrication oil pressure
engine coolant temperature / overheating of engine coolant
engine charge-air temperature
the engine is to be turned off immediately and the cause of the error properly
remedied, i.e. in a specialist workshop.
Do not put this engine into operation again until the error has been eliminated.

22

Commissioning and operation

Operation of the engine monitoring system BE1
The engine monitoring system BE1 warns
the ship operator if important engine operating values are outside the permissible
tolerance range.
The display unit of the engine monitoring
system (see picture) is installed in the
main navigating stand and, as an option,
in the secondary navigating stand (flybridge) too. The alarm is raised:
D acoustically by means of a horn
D visually by the flashing of the respective
red check lamp (exception: in the event
of a fault in the electronic system the
respective check lamp is permanently
illuminated)

To protect the engine, the speed will be reduced if alarm warnings like engine oil pressure, engine coolant temperature, charge-air temperature and coolant level) is raised.
The check lamp reduced speed is then illuminated permanently.
Note on engines with electronically controlled diesel injection (EDC):
After the ignition has been switched on, the lamp Fault in the electronic system
will come on momentarily (lamp check). If there is a fault in the electronically controlled diesel injection system (EDC), the lamp Fault in the electronic system will
be illuminated permanently.

Operation of the engine monitoring system BE1 after an alarm has been triggered
The display unit has the following operating buttons:
Switching off of the alarm horn.
Switching off of the flashing signal of the respective check lamp, ie the flashing
light changes into permanent light. Before the flashing signal can be switched off,
the alarm horn must be switched off.
Lifting of the alarm message (the red check lamp will go out).
Precondition for lifting an alarm message:
D Pressing of buttons Horn off and Test in the order indicated
D Elimination of the cause of the alarm

23

Commissioning and operation

D Short-term reduction of the engine speed below 800 rpm, to again achieve higher engine speeds
Functional test of the check lamps
If no alarm is raised, the check lamps may be checked. Upon pressing the button
Test, all check lamps must come on.
Self-test of system BE1
To achieve optimum operational reliability, the system distinguishes between sensor fault
and real alarm.
The following sensors are checked for
sensor fault and parting of wire:
D
D
D
D
D

Engine speed
Engine oil pressure
Coolant temperature
Charge-air temperature
Coolant level

If the signal sent by the sensor is a value

which does not occur in practice or if the
wire connection is interrupted, the check
lamp Sensor fault and the check lamp of
the associated function will start flashing.

24

Commissioning and operation

The D 2848 LE 401 is equipped with a monitoring and diagnostic system MMDS optionally.
On the control console and alternatively on other control stands, the following display devices are available for monitoring operation:
1. Analog round instruments, see below
2. Display device MMDS-L, see page 26
3. Display device MMDS-LC, see page 28
4. Engine room panel MMDS-EP, see page 35
For operation and speed adjustment, MAN provides the following equipment:
5. Drive lever control system Mini Marex made by Mannesmann-Rexroth, see page 36
1. Round instruments
MAN can supply the following VDO round instruments for operation monitoring:
Revolution counter with integrated digital hours of operation counter
Oil pressure engine
06 bar
Oil pressure gearbox
025 bar
Oil temperature engine
50150C
Coolant temperature engine 40120C
Exhaust temperature engine 100900C
Voltmeter
1832 V

25

Commissioning and operation

2. Display device MMDS-L
The engine monitoring alarms the officer
guiding the ship when important engine
operating values are outside the permitted
tolerance range.

MAN MARINE DIESEL

Acoustically by means of an integrated

buzzer or horn connected at the shipyard
D Visually in that the relevant warning
lamp flashes

Engine in operation

Boost pressure

Generator/speed sensor

Coolant level

Engine oil pressure

Overspeed

Engine coolant temp.

Charge air temperature

Alarm
Cool. press. water pump

Engine slow down

Cool. press. expans. tank

Exhaust gas temperature

Sensor failure

Engine oil temperature

Pressure air filter

The engine operating parameters shown

on the display device are monitored.
If gearbox parameters are to be monitored, this depends whether the corresponding sensors have been fitted in the
gearbox.

TYP MMDSL

Gearbox oil pressure

Gearbox oil temperature
Electronics failure

TEST

RESET

System
Fault

51.277207008

The device distinguishes between the following types of alarm, error messages:
Preliminary alarm:
the corresponding light-emitting diode flashes
Main alarm:
the corresponding light-emitting diode flashes
light-emitting diode Alarm flashes
In the case of an engine slow down alarm, Engine slow down also
flashes
In the case of a stop alarm, Engine stop also flashes
D Sensor fault:
the corresponding light-emitting diode flashes
light-emitting diode Sensor fault flashes
D
D

The alarm Sensor fault means that the corresponding sensor is classified by the monitoring system as defective, as it is returning an unrealistic value.
The engine speed is not reduced.
In the event of a fault in the electronic system, the warning lamp lights up continuously.
There is then a defect in the electronic fuel injection (EDC).
So as not to endanger the engine, the engine power is automatically reduced in the case
of selected main alarms.
Note for engines with electronically controlled diesel injection (EDC):
After the ignition has been switched on, the lamp Electronic fault lights up briefly
(lamp test). If there is a fault in the electronically controlled diesel injection (EDC),
the lamp Electronic fault lights up permanently.

26

Commissioning and operation

Operation of the display device MMDS-L
The display device has the following operating keys:
Switches off the alarm horn and the integrated buzzer
Switches off the flashing signal of the relevant warning lamp, i.e. the flashing light
switches to continuous light. Before the flashing signal is cleared, the alarm horn
must be switched off.
Clears the alarm message (red warning lamp goes out)
Requirement for clearing an alarm message is:
Pressing the keys Horn off and Test in that order
Removing the cause of the alarm
In the event of a reduction alarm the engine speed must be brought down
below 800 rpm in order to be able to reach higher speeds again
In the case of a stop alarm, the alarm can only be deleted if the engine is at a
standstill
Function test of the warning lamps
If there is no alarm, the warning lamps can be tested.
When the Test key is pressed, all the warning lamps must light up
Dimming
All alarm LEDs are dimmed automatically depending on the ambient brightness. A photoelectric element integrated in the front plate ensures this.
Horn test
If the Clear horn key is pressed for approx. 5 seconds, the fitted buzzer as well as possibly horns fitted at the shipyard go off.
System Failure
Two failure states are distinguished and indicated by the failure LED flashing or lighting
up continuously:
A flashing System Failure LED signals a communication fault, i.e. the data bus is interrupted or there is interference. In this case, the seating of plug-in connections for the
MMDS-L and the serial distributor MMDS-SD are to be checked.
D Continuous lighting up of the System Failure LED indicates an internal fault. If this
state remains after switching off and on again, the device is defective.
D

27

Commissioning and operation

3. Display device MMDS-LC
The device serves to visualise analog engine data, as well as visual and acoustic
notification of engine alarms. All engine
data is entered at the factory in the languages German, English, French, Italian and Spanish.

MAN MARINE DIESEL

M Motordrehzahl
1 Oeldruck Motor
Kuehlwassertemp.Motor
A Ladelufttemperatur
3 Oeltemp. Motor

1835 upm
4.3 bar
83 C
64 C
120 C

Engine run
Alarm
System fail.

Scrolling with the PAGE key enables the

user to call up all the important engine
data. Another key is used to show current
alarms or warnings.

TYP MMDSLC

51.277207015
ALARMS

PAGE

RESET

Men

TEST
Prg

Representation of monitor pages

The analog engine data provided by the MMDS is distributed on 4 monitor pages. On
each page, the current engine speed is displayed in the top line. The 1st page continues
with the most important engine data such as oil pressure, coolant pressure, charge-air
pressure and oil pressure in the gearbox. Other engine and gearbox data, as well as exhaust temperatures and supplementary information is shown on the subsequent pages:
Page 1
P1

Actual value (example)

Engine speed

2100

rpm

Oil pressure, engine

4,3

bar

Coolant temperature, engine

82

Charge-air temperature

41

Oil pressure, gearbox

19

bar

Page 2
P2

Actual value (example)

Engine speed

2100

rpm

Coolant pressure compensator

reservoir

830

mbar

Coolant pressure water pump

3,9

bar

Oil temperature, engine

103

Battery voltage

27,1

28

Commissioning and operation

Page 3
P3

Actual value (example)

Engine speed

2100

rpm

Intake air vacuum

30

mbar

Charging pressure

1,86

bar

Exhaust temperature T.A.

629

Exhaust temperature T.B.

613

Page 4
P4

Actual value (example)

Engine speed

2100

rpm

Fuel consumption

162

l/h

Engine load

79

The pages are scrolled using the PAGE key. Each time the key is pressed, the screen
moves up to the next page. After page 4, page 1 appears again.
For the display of current alarms and warnings, an alarm screen has been included. This
is called up using the ALARMS key. If there is no alarm, the message no message
appears on the screen.
A1

> no message

If an alarm is activated, the device switches automatically to the alarm screen. Each new
entry is made in the top line. Any messages that might already be present shift one line
downwards. In a column to the right of this, the code and current time are added. Although a warning (message without alarm) is entered in the alarm screen, there is no automatic switch to that screen, e.g. in the case of a programmed ship alarm or ship-specific warning, see page 34.
The following codes are distinguished:
Warnings:
without code
Warnings (preliminary alarms): WA
Main alarms:
AL
Sensor error alarms:
SE
Example:
Message text
A1

Code

Time

Coolant temperature

WA

14:14

Charge-air temperature

SE

13:57

Coolant level

11:00

Oil pressure, engine

AL

08:37

Bilge pump ON

Programmed ship-specific warning

If there are more than 5 alarms (e.g. during commissioning in the shipyard), the alarms
can be displayed in groups of five (A2 to An) by pressing the ALARMS key again.
All alarms are always displayed in reverse order of their occurrence. The alarm generated last is therefore located in the first line of the alarm screen. As long as at least one
alarm is active, the red LED Alarm to the right of the display lights up.

29

Commissioning and operation

Alarms
If an engine alarm from the central unit MMDS or an alarm configured by the user is issued, the built-in buzzer is activated and the LED Alarm flashes. At the same time, the
monitor switches automatically to the alarm screen. The new alarm is entered in the first
line as a flashing message.
The alarms that would be issued if the engine is stopped but the engine ignition is on
(e.g. lack of oil pressure) are suppressed (disabled) until the green LED Engine run
lights up. This occurs approx. 8 seconds after ignition engine speed has been reached.
When the acoustic acknowledgement (Horn Quit key) has been pressed, the integrated
buzzer switches off. With the visual acknowledgement (Visual Quit key), the flashing text
and the LED Alarm switches to continuous display. When the fault has been remedied,
the alarm text disappears from the monitor. The LED Alarm goes out unless another
alarm has been issued.
In the case of alarms that have led to automatic stopping or reduction of the engine speed by the central unit MMDS, the RESET key must also be pressed. This
function is only enabled in the case of a stop alarm at engine standstill and in the
case of a slow down alarm below an engine speed of 800 rpm.
Horn test
If the Clear horn key is pressed for approx. 5 seconds, the built-in buzzer sounds.
System Failure
The front plate of the device has a red LED with the description System Failure. This is
activated in the following two cases:
A Failure of the serial data from the Safety, Alarm and Diagnosis system MMDS in the
engine terminal box. In this case, LED Alarm also flashes and the message System
Failure appears on the alarm screen.
B Fault in the LCD monitor itself. In this case, no other message appears.
Key functions
The front of the device has 5 keys that enable various functions such as scrolling, contrast adjustment, alarm acknowledgement and menu control. The keys have the following
functions: Standard, Test, Menu and Special functions.
Horn Quit:

P rg

Standard function: acoustic acknowledgement or deactivation of the internal horn.

All other monitoring devices in the system are acknowledged via the
serial bus.
Test function: Holding the key for at least 5 seconds activates the built-in
buzzer.
PRG menu function: adopt currently selected setting (Prg=program)
30

Commissioning and operation

Visual Quit / Test:
Standard function: visual acknowledgement,
i.e. all flashing alarm texts in the currently visible alarm screen switch to
TES T
constant representation if the horn was acknowledged beforehand; the
red alarm LED integrated in the front plate is also switched from flashing
to continuous lighting. All other monitoring devices in the system are acknowledged via the serial bus.
Test function if there is currently no alarm and / or all issued alarms have
been visually acknowledged beforehand: Lamp test, i.e. the three LEDs
in the front plate are activated as long as the key is pressed.
P AG E

Special function: see explanation of key

+-menu function: Shift selection cursor to the right or increase input value.
RESET:
R E S ET

Standard function: The reset key can be used to reset a slow down or
stop alarm:
A reduction alarm can only be reset after reduction of the speed
below 800 rpm.
If the corresponding criteria have been met, horn and optics / test button
pressed / activated and the cause of the alarm eliminated, the reduction
or stop alarm in the central processing unit is reset.
P AG E

Special function: see explanation of key

-menu function: Shift selection cursor to the left or decrease input value.
PAGE:
P AG E

Standard function: Switch to next highest display screen for analog engine data. The page number is indicated in the top left-hand side of the
display with P1 to P4. Page 4 is followed again by page 1. If this key is
pressed while the alarm screen is on display, the monitor switches back
to the analog engine data from which the alarm screen was originally
called.
-Special

function: Key enables setting of the LCD contrast with simultaTES T

neous pressing of the keys

ALARMS:
ALARMS
M en

R E S ET

or

Standard function: Calling up the alarm screen; the five alarms or warnings last issued and still present are displayed. At the top left of the monitor is the code A1. If there are more than 5 messages issued, the messages can be displayed in groups of five by pressing the key again. The
page number is indicated in the top left with A1 to Ax. If the display jumps
to the 1st alarm screen or the display remains unchanged when the key
is pressed, no more messages are active.
Special function: Holding the key for at least 5 seconds activates the
built-in configuration menu. There, the language, units, date and time
can be set.
Menu function: Within the menu, this key has a cancel function (Esc).
The program moves back by one menu level and / or from the main
menu to the normal display function.

31

Commissioning and operation

Menu functions
By holding the ALARMS key (for at least 5 seconds), you enter the configuration menu.
The keys are now given the significance described at Menu function. The new allocation is shown in the bottom line in continuous black:
Escape function
Cancel

Move function
Move selection cursor

Enter function
Accept setting

esc(Men)

move(+/)

enter(Prg)

Menu guidance is in English and cannot be changed. You first enter the main menu,
where the language and units for measurement point designations and measured values
can be selected. There are also additional sub functions for time setting (set-time), as
well as service functions, incl. PC communication (service). Each current selection can
be cancelled using the Escape function (menu key

ALARMS
M en

). All other previously made set-

tings are not influenced by this.

Selection of language and units
When the menu is opened, the current settings are shown highlighted in black. A flashing
selection cursor marks the language currently set (e.g. English):
English

German

> (US/GB) <

French

(D)

Italian

(F)

Spanish

(I)

(E)
TES T

The selection cursor can be moved using the Move function (+ keys
Enter function (PRG key

P rg

R E S ET

). The

) is used to accept each marked language and highlight it

in black. The selection cursor then returns to the currently set unit for temperatures (e.g.
F):
Display in degrees Celsius

Display in degrees Fahrenheit

(C)

> (F) <

TES T

Selection is again using the Move function (+ keys

ance using the Enter function (PRG key

P rg

R E S ET

) followed by accept-

). The selection is highlighted in black and

the selection cursor jumps to the currently set unit for pressures (e.g. bar).

32

Commissioning and operation

Display in BAR

Display in PSI

> (BAR) <

(PSI)

After selection and acceptance, all the settings for language and unit have been concluded and highlighted accordingly in black. The selection cursor jumps to the second
last line to the item exit:
>exit<

back

set-time

service

If this is confirmed using the Enter function (PRG key

using the Escape function (Menu key

ALARMS

P rg

) or you cancel at this point

), you return with the currently marked mode

M en

to the normal display function. In the event of an input error, you can use the function
back to repeat the input. The selection cursor jumps back to the initial position (language selection).
Setting the time
First, the selection cursor must be placed in the second last line. To do so, the current
language and unit settings are confirmed each time with the key
TES T

back

> set-time <

. The

selection

R E S ET

cursor can now be positioned using the + keys

exit

P rg

to set-time.
service

The function is called up using the PRG key

P rg

A new page is opened and the current time (time / date) is displayed.
The selection cursor jumps to Hour.
set-time

hour

minute

second

time

(H:M:S)

>13<
day

29
month

56
year

date

(D:M:Y)

27

06

00

If nothing is to be changed, you can cancel using the Menu key

TES T

ALARMS
M en

Otherwise, the

R E S ET

setting is made using the + keys

and the PRG key

P rg

in the order Hour,

Minute, Second, Day, Month and Year. A correctly specified time or date is confirmed
using the PRG key

P rg

and the selection cursor jumps to the next value. The year is

given last, and the selection cursor jumps to the second last line to the item exit; the
time setting is now concluded.

33

Commissioning and operation

>exit<

Back

get-mmds-time

You return to the main menu by pressing the PRG key

P rg

or the Menu key

ALARMS
M en

In

the event of an input error, you can use the function back to repeat the input.
An additional function makes it possible to download the system time of the MMDS central unit into the display module. To do so, the selection cursor is placed on get-mmdstime and confirmed with PRG

P rg

. If

the central unit is active (engine ignition on), the

date and time are overwritten and the following message appears briefly in the display.
>>> LOAD MMDS-SYSTEM-TIME <<<

If the central unit is switched off (engine ignition off), nothing is changed and the following
message appears:
>>> NO MMDS-TIME RECEIVED <<<

The selection cursor then jumps back to the second last line to the item exit:
Ship-specific alarms
There is the possibility to connect 11 ship-specific alarms or warnings and to generate
these using software. The text of the alarms or warnings is entered by the shipyard.
In the event of an alarm, the corresponding measurement point text appears on the
alarm page; the program switches automatically into the alarm menu. In the case of
warnings, the program does not switch automatically into the alarm menu.

34

Commissioning and operation

4. Engine room panel MMDS-EP

MAN MARINE DIESEL

M Motordrehzahl
1 Motoroeldruck
Kuehlwassertemp.
A Ladelufttemperatur
3 Motoroeltemperatur

1835 upm
4.3 bar
83 C
64 C
120 C

Engine run

Alarm
System Fail.

51.277207018
ALARMS

TYP MMDSEP
PAGE

RESET

TEST

Men

Prg

The functions of the keys and of the LCD displays are the same as those on the
MMDS-LC (see operating instructions for MMDS-LC).
Differences to MMDS-LC:
D no ship-specific alarms can be programmed
D additional:
Ignition
Pre-glow plug
Note on pre-glow plug:
The pre-glow plug is not active in the in-line 6-cylinder engine (D 2876
LE401/404), as this engine is not equipped with a pre-glow system.
On V-engines, pre-glow can be fitted as an option. In ignition position I, the
lamp lights up. Wait until the lamp begins to flash, then start.

35

Commissioning and operation

5. Drive lever control system Mini Marex
Danger:
For safety reasons a separate, functioning red emergency-stop-button for each
engine must be installed at every bridge (the engine must stop immediately when
the button is pressed once).
At the request of the shipyard or customer, it is possible to purchase from MAN an electronic drive lever control system made by Mannesmann Rexroth, type Mini Marex.
This control system has plug connections specially configured for MAN.
Operation of the control system:
Command master
Gearbox forwards
(lock)

Neutral
(lock)

Gearbox reverse
(lock)

Infinitely variable
speed adjustment

Infinitely variable
speed adjustment

Reverse area

Forwards area

3
Operating field
Max. speed

Max. speed

Acoustic
signalling
device

Neutral (lock) position

In this position, the gearbox clutch is disengaged and the power unit is idling. Each time
the Neutral position is reached, the control system indicates this acoustically by means
of a short beep tone.
Gearbox forwards / reverse (lock) position
In this lever position, two different functions are possible.
1. Standard function:
The gearbox clutch is engaged to Forwards or Reverse; the power unit is idling.

36

Commissioning and operation

2. Increase engine speed function:
The Increase engine speed function is set (function switch II8). The engine speed
of the power unit is raised prior to engaging the clutch and after disengaging the clutch
it is lowered again to idling speed. Between the clutch engaging operations, individual
delays (waiting periods BEFORE and AFTER clutch engaging) can be set.
Maximum engine speed position
Position shows the maximum engine speed for the Forwards and Backwards
Range.
Between positions and , the engine speed can be set variably.
The gearbox clutch is engaged to Forwards or Reverse.
Operating panel command master for twin-engine systems

L1

L2

L3

L4
L5 L6

COMMAND
SYNCHRO
TROLLING
COMMAND

T1

L7

SYN./TROL.

L8

T2

Key Command takeover T1

COMMAND

The Command takeover key occurs only once on the command master. The
key is permanently illuminated weakly via LED L1 and indicates that the control
system is being supplied with voltage. The key serves to take over commands
onto the relevant control stand.
The key has two other additional functions.

Additional function Warming Up

The expression Warming Up means engine running without shifting gear, which enables, for example, warm-up of a cold power unit across the entire speed range. The
gearbox clutch is not engaged in lever position .
Starting the Warming Up function:
. The Warming Up function can only be started at an active command master and only
from the position neutral.
1. Set the control lever of the command master in position neutral.
37

Commissioning and operation

2. Press the key Command takeover and keep it pressed.
3. Set the control lever of the command master in position gearbox forwards / reverse.
The Warming Up function is indicated acoustically by a short double beep tone
and visually by a brief, rhythmic extinguishing of the command master lighting.
4. Release the Command takeover key.
The engine idles and the gearbox clutch remains disengaged. The control lever can now
be moved towards position maximum engine speed. The entire engine speed range
between the positions and is available.
. In the case of twin-engine systems, any power unit can be run separately.
Quitting the Warming Up function:
To exit from the Warming Up function, the control lever of the command master must be
set to position neutral. The normal beep tone sounds for the Neutral position. The
command master lighting returns to continuous light. The function is disabled.
If the control lever is shifted from Forwards to Reverse or vice versa during the
Warming Up function, the Warming Up function stops automatically when position
neutral is reached. When position gearbox forwards / reverse is reached
again, the gearbox clutch would be engaged again.

Additional function: switch error message to mute

The acoustic signal transmitter, which is activated for some alarms, can be disabled at
the relevant control stand by pressing the Command takeover key.
. However, this does not delete the alarm!
Display Alarm L7 and L8

This display element is present on the command master twice (once for the port system /
once for the starboard system). In the event of a fault, the Alarm lamp lights up continuously in red.
. When the control system is switched on, the Alarm lamp is also lit up continuously in
red, but this is extinguished following command takeover.
Key Syn./Trol. T2
This key can be used to ENABLE and DISABLE special functions enabled beforehand in the setting unit (key is permanently illuminated weakly via LED 6).
SYN/TROL

The following special functions are available for this setting unit:
38

Commissioning and operation

1. Engine speed synchronisation (only twin-engine systems)
2. Trolling
The Syn./Trol. key can be used to operate both functions in parallel, but not simultaneously.
Engine speed synchronisation (only possible with twin-engine systems)
If the special function Engine speed synchronisation has been enabled in the setting
units, twin-engine systems provide the possibility to synchronise the engine speeds of
both drive engines. For both drive engines to run synchronously, an engine speed feedback signal from a speed sensor is required for each engine.

SYN/TROL

Pressing the Syn./Trol. key (press once) enables the Engine speed synchronisation function. Pressing the key again (press once) disables the function once
again.
It is only possible to enable or disable the engine speed synchronisation on the
active control stand when both command master levers are in the engine speed
range Forwards or during the Warming Up function. Before exiting from these
areas, disable the engine speed synchronisation.
While the function is active, LED 4 SYNCHRO shows continuous light.

. As soon as one of the command masters leaves the engine speed range Forwards
without terminating the synchronisation beforehand, it is switched off automatically.
In this case, the LED SYNCHRO flashes rapidly (approx. 0.2 seconds on / 0.2 seconds off) and the acoustic signal transmitter issues a continuous tone at the active
control stand (this is not a fault alarm but a warning).
The second command master must then be set into the Neutral position to terminate
the warnings. The engine speed of the relevant command master is kept at idling
speed during this period.
While the control system is in the function Synchronisation, the engine speeds of both
power units can only be changed using the control lever of the Master system. If there
is a command change to another control stand, the active function Engine speed synchronisation is also taken over onto the new control stand.
Trolling
If the special function Trolling has been enabled in the setting units, there is the possibility to use the Syn./Trol. key to enable the trolling mode to continuously adjust the
clutch slip.

39

Commissioning and operation

SYN/TROL

Pressing the Syn./Trol. key (press once) enables the Trolling function. Pressing again (press once) disables the function once again.
It is only possible to enable or disable the trolling function on the active control
stand when the command master lever (both command master levers in the case
twin-engine systems) is (are) in the Neutral position. While the function is active, LED L8 Trolling shows continuous light.
If there is a command change to another control stand, the active function Trolling is also taken over onto the new control stand.

. In the trolling mode, the command master function changes in comparison to

the power shift mode.
The command master function in the trolling mode is described below.

Gear: forwards
Clutch: 100% slip
(lock)

Neutral
(lock)

Gear: reverse
Clutch: 100% slip
(lock)

Infinitely variable
slip adjustment and
speed increase

Infinitely variable
slip adjustment and
speed increase

Reverse area

Forwards area

3
Operating field
Clutch: 0% slip (grip)
and max. speed
when trolling

Clutch: 0% slip (grip)

and max. speed
when trolling

Acoustic
signalling
device

To enable the trolling function, the command master must be in position Neutral
(lock). The engine idles and the gearbox is in neutral.
If the trolling mode is enabled, the clutch is set to its highest slip level (100% slip). The
engine continues to idle and the gearbox is in neutral.
If the command master lever is set in position (lock), the gearbox is shifted into the
Forwards or Reverse position. The engine idles, but due to the greatest possible clutch
slip (100% slip) is not yet able to turn the propeller shaft, or can do so only very slowly.
If the command master lever is moved further towards position , the clutch slip drops
continuously and at the same time the engine speed rises.

40

Commissioning and operation

When position is reached, the clutch is in the smallest possible slip position (0% slip /
frictional connection) and the engine speed has reached the set value for Maximum engine speed for trolling.
Acoustic signal transmitter
The acoustic signal transmitter is located below the command master and is
present once on each system (once for the port system and once for the starboard system).
The signal transmitter supports the visual displays of the command master lighting and the alarm lamp with acoustic signals. In addition, each time the Neutral
position of the control lever is reached, it issues a short beep tone. The start of
the Warming Up function is indicated by a short double beep tone.
Display Command L2 and L3
COMMAND

Continuous light of the Command display indicates which command master is currently
in command. The Command displays of the other control stands are disabled. If the
command is requested on this master, the Command display flashes.
If the command master is in the Warming Up function, this is indicated by a brief,
rhythmic extinguishing of the Command display.
The Command display is present on the system once (once for the port system / once
for the starboard system).
Enabling the control system with command masters
1. Switch on control system
Execution:

apply supply voltage.

Consequence:
Display Alarm (red) on all control stands lights up continuously.
Command and Syn./Trol. keys. On all control stands weakly
lit up (only visible in darkness).
Acoustic signal transmitter sounds with slow intermittent tone on all
control stands.
2. Command request:
The command can be requested at any control stand. The control levers of the command
master on the requesting control stand must be set at the Neutral position.

41

Commissioning and operation

. Command master calibration and enable of control stands must have been carried
out.
Otherwise, the command can only be taken over at control stand 1.
Execution:

Set the control lever of the command master to the Neutral position.
Press Command key once for command request.

Consequence:
Display Alarm (red) on all control stands remains lit up continuously.
Acoustic signal transmitter sounds with fast intermittent tone on all
control stands.
The display Command flashes rapidly.
. If the control system continues to issue long lighting and tone intervals, it is usually the
case that the control lever of a command master is not in the Neutral position.
3. Command takeover:
Execution:

Press Command key once again for confirmation of command request.

Consequence: Display Alarm (red) goes out on all control stands.

Acoustic signal transmitter remains silent on all control stands.
Command display shows continuous light on the command master in
command.
On all other command masters, the Command display is off.
The command is now at this control stand. The control system is ready for operation
(standby).
Command change between control stands
For a command change to a different control stand, there are two variants which have to
be set using DIP switch I2 in the setting unit. Command change with lever comparison
or free command change.
On twin-engine systems, both setting units must have the same setting.
. Command master calibration and enable of control stands must have been
carried out.
Otherwise, the command can not be changed between the individual control stands.
Command change with lever comparison
The control system compares the lever positions of the command masters involved in the
control stand change. A command change from one control stand to another can only
take place if the lever of the requesting command master is either in the Neutral position or in the same travel direction position as the lever of the command master that
is in command.
The command change for this variant takes place in two steps.

42

Commissioning and operation

1st step: Command request on the selected control stand.
Execution:

Set the control lever of the command master in the takeover position
(Neutral position or same travel direction as the command master that
is in command).
Press Command key once to request the command on this controlstand.

Consequence: The acoustic signal transmitter beeps in short intervals.

The display Command flashes rapidly.
The command is now requested on this control stand. The control system has enabled
the command takeover and indicates this by means of short tone and lamp intervals.
. If the control system issues long lamp and tone intervals, the subsequent command
takeover is refused. In this case, the control levers of the command master are usually
not in the correct position or there is a fault in the system.
2nd step: Command takeover on the selected control stand.
Execution:

Press Command key once to take over the command on this control
stand.

Consequence: The acoustic signal transmitter is silent.

The Command display shows continuous light.
The command takeover is complete and the command is now at this control stand.
Free command change (without lever comparison)
With this variant, a control stand change takes place without taking account of the lever
position of the command master involved in the command change. The command
change takes place in one step.
Command takeover on the selected control stand
Execution:

Press Command key (white) to take over the command on this control stand.

Consequence: The Command display on the selected control stand immediately

shows continuous
light.
The command is immediately at this control stand and the control system instantly runs
the lever position of the command master set here.
In this variant, carelessness can lead to manoeuvres that are not intended.
Example: Lever of the active command master is in position Full forwards.
Lever of the requesting command master is in the position Full reverse. If there were
a command change, a full reverse manoeuvre would be performed immediately.
43

Commissioning and operation

Shutting down
After the engine has been running at a high load level, do not shut it down immediately
but allow it to idle about 5 minutes so that temperatures may equalize.
Set deck switch to Neutral and switch off the engine at the ignition key.
Remove key from starting lock.
Danger:
Ensure that the engine can not be started by unauthorized persons.

44

Maintenance and care

Lubrication system
Ensure outmost cleanliness when handling fuels, lubricants and coolants.
Note:
Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc.).
Otherwise the manufacturers warranty will become null and void.
Engine oil change
Danger:
The oil is hot- risk of scalding.
Do not touch the oil drain plug
with bare fingers. Oil is an environmental hazard. Handle it with
care!
With the engine at operating temperature,
remove the oil drain plugs on the oil sump
and the oil filter bowl and allow the old oil
to drain off completely.
Use a vessel of sufficient size to ensure
that the oil does not overflow.
As the oil drain plug is often not accessible, a manually operated vane pump may
be attached to the engine for draining the
oil.
Pump the old oil out of the sump while the
engine is still warm. Remove oil drain
plugs in oil filter bowl and let old oil drain
out of oil filters. Use a vessel of sufficient
size to ensure that the oil does not overflow.
Refit the oil drain plugs with new gaskets.
Note:
Change the oil filter elements every time the engine oil is changed

45

Maintenance and care

Refilling with oil

Oil

Caution:
Do not add so much engine oil
that the oil level rises above the
max. marking on the dipstick.
Overfilling will result in damage to
the engine.
Refill with fresh engine oil at the oil filler
neck (arrow).
After filling start the engine and let it run
for a few minutes at low speed.
Caution:
If no oil pressure builds up after
approx. 10 seconds switch off the
engine immediately.
Check oil pressure and check that there is
no oil leakage.
Then shut down the engine. After about
20 minutes, check the oil level.

Oil

D Pull out dipstick (arrow)

D wipe it with a clean, lintfree cloth
D and push it in again up to the stop

MAX

D Pull out dipstick again

MIN

The oil level should be between the two

notches in the dipstick and must never fall
below the lower notch. Top up oil as necessary.
Changing oil filter
A changeover-type oil filter, the filter elements of which can be replaced even during operation, can be fitted on request.
However, oil filter cartridges must be
changed at every oil change.
46

Maintenance and care

During continuous operation position the
selector lever that both filter halves are in
operation.
Observe positions of selector lever!

Continuous operation
(both filter halves
in operation)
Right-hand filter
cut out

Caution:
Do not leave selector lever in any
intermediate position because this
would be liable to interfere with oil
supply. If in doubt stop engine to
change oil filter.

Left-hand filter
cut out

Renewal of filter cartridges

D Allow the filter content to run off along
drain plugs .
Hold a suitable vessel under hole

1
8

Danger:
The oil is hot and under pressure
when the drain plug is opened.
Risk of burns and scalds.

D After releasing the clamping bolts

remove filter bowls
D Renew filter cartridges . Thoroughly
clean all other parts in cleaning fluid
(do not allow cleaning fluid to enter the
oil circuit)
D Use new gaskets for reassembly of
filter bowls

4
3

Note:
To prevent the seal from twisting hold the filter bowl firmly
when tightening the tensioning
screw .

1 Oil filter, standard design

(non-changeover)
2 Oil filter, changeover-type
3 Selector cock
4 Oil drain plugs
5 Filter cartridge
6 O-ring
7 Filter bowl
8 Clamping bolt

Caution:
Used oil filters are classed as dangerous waste and must be disposed of accordingly.

47

Maintenance and care

Fuel system
Fuel
If Diesel fuel which contains moisture is used the injection system and the cylinder liners
/ pistons will be damaged. This can be prevented to same extent by filling the tank as
soon as the engine is switched off while the fuel tank is still warm (formation of condensation is prevented). Drain moisture from storage tanks regularly. Installation of a water trap upstream of the fuel filter is also advisable. Do not use any additives to improve
flow properties in winter.
Note:
Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc.).
Otherwise the manufacturers warranty will become null and void.
Injection pump
Neither the injection pump nor the control unit must be modified in any way. If the lead
seal is damaged the engine warranty will become null and void.
Faults
We urgently recommend that you have faults in the injection pump rectified only in an authorized specialist workshop.

Cleaning fuel pre-cleaner

D Strip the fuel pre-cleaner
1

D Wash out filter housing and filter basket in clean fuel

2
3

D Fit new seals

D Actuate tappet of hand primer until

overflow valve of injection pump is
heard to open
D Screw in the tappet of the hand pump
again and tighten it
D Start engine
D Check fuel pre-cleaner for leaks

48

Maintenance and care

Parallel fuel filter
Draining moisture:
Unscrew drain plugs at every oil change
until moisture has been discharged and
clean fuel flows out.

Changing fuel filter

Only when engine is switched off
D Loosen filter with tape wrench and
remove it
D Wet seal on new filter with fuel
D Screw on filter by hand
D After this, bleed the fuel system
D Check filter for leaks
Caution:
Used fuel filters are classed as
dangerous waste and must be disposed of accordingly.

Change-over fuel filter

Continuous operation
(both filter halves
in operation)

Where the changeover-type filter is

installed, the servicing procedure is for the
filter side requiring to be shut off with the
engine running. During continuous operation, the selector lever should be placed
in a position where both filter halves are in
operation.

Right-hand filter
cut out
Left-hand filter
cut out

Caution:
Do not leave selector lever in any
intermediate position because this
would be liable to interfere with
fuel supply. If in doubt stop the
engine to change the fuel filter.

49

Maintenance and care

Changing fuel filter
D Loosen filter with tape wrench and
remove it
D Wet seal on new filter with fuel
D Screw on filter by hand
D After this, bleed the fuel system
D Check filter for leaks
Caution:
Used fuel filters are classed as
dangerous waste and must be disposed of accordingly.

Bleeding the fuel system

Note:
To bleed the fuel system switch on
the ignition so that the EHAB will
be open.
An arrow on the filter head indicates the
direction of fuel flow.
D Unscrew bleed screw of first filter in
direction of flow by one or two turns
D Actuate tappet of hand primer until fuel
emerges without bubbles
D Screw in the tappet of the hand pump
again and tighten it
D Close bleed screw again
D Repeat this procedure at the second
bleed screw
D Check filter for leaks

50

Maintenance and care

Cooling system
Danger:
Draining hot coolant involves a risk of scalding.
Draining the cooling system

Caution:
Drain coolant into a suitable container and dispose of it in accordance with regulations.
Drain coolant as follows, but only when
the engine has cooled down.

D Briefly open cap (, large cap) on the

filler neck of the expansion tank for
pressure compensation

D Remove drain plug in crankcase , oil

cooler housing and exhaust
manifold

D Then remove cap

2
D Drain coolant into a container of adequate size

D Refit screw plugs

D Filling / bleeding the cooling system

51

Maintenance and care

Filling / bleeding the cooling system (only when engine has cooled down)
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze
agent on ethylene glycole basis or anti-corrosion agent.
See Publication Fuels, Lubricants and Coolants for MAN Diesel Engines.
Coolant must be added at the filler neck only (, large cap). When topping up do not
add cold coolant if the engine is still warm from operation.
Ensure that the ratio of water to anti-freeze is correct. Find the cause of the loss of coolant and have it eliminated.
D Remove cap (, large cap)

D Fill in the coolant slowly

D During the filling operation the liquid
cooled turbochargers are to be bled.
For this purpose an oval flange with a
bleeder screw is located on the rear
side of the turbine housing. This
bleeder screw must remain open until
coolant emerges free of bubbles or until
the coolant level has reached the filler
neck (depending on the installation
situation)
D Let engine run at a speed of 2,000 rpm
for approx. 15 minutes
2

D Switch off engine, carefully turn cap

with safety valve to the first detent to
relieve pressure and then carefully remove cap and top up with coolant
Caution:
Risk of scalding and burning
yourself!

52

Maintenance and care

D Before the engine is next put into operation (with the engine cold) check the coolant
level and top up if necessary
D Repeat this procedure until no more coolant can be added
Note:
The turbochargers must not be bled while the cooling system is being topped up.
Danger:
If, in an exceptional case, the coolant level has to be checked in an engine that
has reached operating temperature, first carefully turn the cap (, large cap)
with safety valve to the first stop, let off pressure, then open carefully.

53

Maintenance and care

V-belts
Checking condition

If, in the case of a multiple belt drive, wear

or differing tensions are found, always replace the complete set of belts.
D Check V-belts for cracks, oil, overheating and wear
D Change demaged V-belts
2
Checking tension
Use V-belt tension tester to check V-belt
tension.
D Lower indicator arm into the scale
D Apply tester to belt at a point midway
between two pulleys so that edge of
contact surface is flush with the
V-belt
D Slowly depress pad until the spring
can be heard to disengage. This will
cause the indicator to move upwards

Drive
belt
width

If pressure is maintained after the spring

has disengaged a false reading will be obtained!
Reading of tension
D Read of the tensioning force of the belt
at the point where the top surface of
the indicator arm intersects with the
scale
D Before taking readings make ensure
that the indicator arm remains in its
position
If the value measured deviates from the
setting value specified, the V-belt tension
must be corrected.

54

Tensioning forces according to

the kg graduation on the tester
When
servicing
After 10
after
Installamin. run- long runtion
ning time ning time
New installation

9.5

4550

4045

30

10.0

4550

3540

30

12.5

5055

4550

35

13.0

5055

4045

35

20.0

75

70

60

22.0

75

70

60

2/3VX

90100

7080

60

3/3VX

135150 105120

90

Maintenance and care

Tensioning and changing V-belt
D Remove fixing bolts
D Remove lock-nut
D Adjust nut until V-belts have correct
tensions
D Retighten lock-nut and fixing bolts

1
3
1

To replace the V-belts loosen lock-nut and

swing alternator inwards.

Alternator
The alternator is maintenance-free.
Nevertheless, it must be protected against dust and, above all, against moisture.
In order to avoid damage to the alternator, observe the following instructions:
While the engine is running
D Do not de-energize the main battery switch!
D Do not disconnect the battery or pole terminals or the cables!
D If, durig operation, the battery charge lamp suddenly lights up, stop the engine immediately and remedy the fault in the electrical system!
D Do not run the engine unless the battery charge control is in satisfactory order!
D Do not short-circuit the connections of the alternator with those of the regulator or said
connections with ground, not even by briefly bringing the connections into contact!
D Do not operate the alternator without battery connection!

Temporary decommissioning of engines

Temporary anti-corrosion protection according to MAN works norm M 3069 is required for
engines which are to be put out of service for fairly long periods.
The works standard can be obtained from our After-Sales Service department in Nuremberg.

55

Technical data

Model

D 2848 LE 401 / 403 / 405

Design

V 90

Cycle

4-stroke Diesel with turbocharging /

intercooling and wastegate

Combustion system

Direct injection

Turbocharging

Turbocharger with intercooling

and wastegate

Number of cylinders

Bore

128 mm

Stroke

142 mm

Swept volume

14 620 cm3

Compression ratio

13.5 : 1

Rating

see engine nameplate

Firing order

15726348

Valve clearance (cold engine)

Intake
Exhaust
Valve clearance changed
Intake
Exhaust
See instruction label on valve cover

0.25 mm
0.40 mm
from engine No. ... 7678 001 ....
0.50 mm
0.60 mm

Valve timing
Intake opens
Intake closes
Exhaust opens
Exhaust closes

24 before TDC
36 after BDC
63 before BDC
27 after TDC

56

Technical data

Fuel system
Injection

In-line pump, V-saddle-mounted

Governor

Centrifugal governor (variable-range

speed governor) with smoke stop

Start of delivery
22 1 before TDC

D 2848 LE 401
D 2848 LE 403
up to engine No. ... 9211 019 ....
from engine No. ... 9211 020 ....

24 1 before TDC
18 1 before TDC

D 2848 LE 405
up to engine No. ... 9261 016 ....
from engine No. ... 9261 017 ....

21 1 before TDC
15 1 before TDC

Injectors

five-hole nozzles

Opening pressure of injector

New nozzle holder:
Used nozzle holder:

295 + 8 bar
280 + 8 bar

Engine lubrication

Force feed

Oil capacity in oil sump (litres)

deep
shallow

min.

max.

12 l
20 l

18 l
24 l

Oil change quantity (with filter)

deep
shallow

21 l
27 l

Oil pressure during operation (depending on oil temperature, oil viscosity

class and engine rpm)

must be monitored by oil pressure monitors / gauges

Oil filter

Full flow filter with two paper cartridges

Engine cooling system

Liquid cooling

Coolant temperature

8085C, temporarily 90C allowed

Coolant filling quantity

63 l

Electrical equipment
Starter

24 V; 5,4, 6.5 kW

Alternator

28 V; 55, 110, 120, 225 A

57

Technical data

Model

D 2840 LE 401 / 402 / 407

Design

V 90

Cycle

4-stroke Diesel with turbocharging /

intercooling and wastegate

Combustion system

Direct injection

Turbocharging

Turbocharger with intercooling

and wastegate

Number of cylinders

10

Bore

128 mm

Stroke

142 mm

Swept volume

18 270 cm3

Compression ratio

13.5 : 1

Rating

see engine nameplate

Firing order

16510273849

Valve clearance (cold engine)

Intake
Exhaust
Valve clearance changed
Intake
Exhaust
See instruction label on valve cover

0.25 mm
0.40 mm
from engine No. ... 7661 035 ....
0.50 mm
0.60 mm

Valve timing
Intake opens
Intake closes
Exhaust opens
Exhaust closes

24 before TDC
36 after BDC
63 before BDC
27 after TDC

58

Technical data

Fuel system
Injection

In-line pump, V-saddle-mounted

Governor

Centrifugal governor (variable-range

speed governor) with smoke stop

Start of delivery
24 1 before TDC

D 2840 LE 401
D 2840 LE 402
with optimised consumption
with optimised NOx

15 0,5 before TDC

12 0,5 before TDC

D 2840 LE 407
with optimised consumption
with optimised NOx

24 0,5 before TDC

22 0,5 before TDC

Injectors
D 2840 LE 401 / 407
D 2840 LE 402

five-hole nozzles
six-hole nozzles

Opening pressure of injector

New nozzle holder:
Used nozzle holder:

295 + 8 bar
280 + 8 bar

Engine lubrication

Force feed

Oil capacity in oil sump (litres)

deep (front end sump)
deep (rear end sump)
shallow

min.

max.

14 l
26 l
26 l

22 l
30 l
30 l

Oil change quantity (with filter)

deep (front end sump)
deep (rear end sump)
shallow

25 l
33 l
33 l

Oil pressure during operation (depending on oil temperature, oil viscosity

class and engine rpm)

must be monitored by oil pressure monitors / gauges

Oil filter

Full flow filter with two paper cartridges

Engine cooling system

Liquid cooling

Coolant temperature

8085C, temporarily 90C allowed

Coolant filling quantity

80 l

Electrical equipment
Starter

24 V; 6.5 kW

Alternator

28 V; 55, 110, 120, 225 A

59

Technical data

Model

D 2842 LE 401 / 402 / 403 / 406 / 408

D 2842 LE 411 / 412 / 413

Design

V 90

Cycle

4-stroke Diesel with turbocharging /

intercooling and wastegate

Combustion system

Direct injection

Turbocharging

Turbocharger with intercooling

and wastegate

Number of cylinders

12

Bore

128 mm

Stroke

142 mm

Swept volume

21 930 cm3

Compression ratio

13.5 : 1

Rating

see engine nameplate

Firing order

112583106721149

Valve clearance (cold engine)

Intake
Exhaust
Valve clearance changed
Intake
Exhaust
See instruction label on valve cover

0.25 mm
0.40 mm
from engine No. ... 7651 046 ....
0.50 mm
0.60 mm

Valve timing
Intake opens
Intake closes
Exhaust opens
Exhaust closes

24 before TDC
36 after BDC
63 before BDC
27 after TDC

Fuel system
Injection

In-line pump, V-saddle-mounted

Governor

Centrifugal governor (variable-range

speed governor) with smoke stop

60

Technical data

Start of delivery
22 0,5 before TDC

D 2842 LE 401 / 402

D 2842 LE 403
with optimised consumption
with optimised NOx

15 0,5 before TDC

12 0,5 before TDC

D 2842 LE 406
with optimised consumption
with optimised NOx

24 0,5 before TDC

21 0,5 before TDC

D 2842 LE 408
with optimised consumption
with optimised NOx

20 0,5 before TDC

18 0,5 before TDC

D 2842 LE 411
D 2842 LE 412
D 2842 LE 413

18 0,5 before TDC

13 0,5 before TDC
16 0,5 before TDC

Injectors
D 2842 LE 401 / 402 / 406 / 408 / 411
D 2842 LE 403 / 412 / 413

five-hole nozzles
six-hole nozzles

Opening pressure of injector

New nozzle holder:
Used nozzle holder:

295 + 8 bar
280 + 8 bar

Engine lubrication

Force feed

Oil capacity in oil sump (litres)

deep
semi-shallow
for 38 / 45 tilt

min.

max.

24 l
22 l
37 l

32 l
30 l
45 l

Oil change quantity (with filter)

deep
semi-shallow
for 38 / 45 tilt

35 l
33 l
48 l

Oil pressure during operation (depending on oil temperature, oil viscosity

class and engine rpm)

must be monitored by oil pressure monitors / gauges

Oil filter

Full flow filter with two paper cartridges

Engine cooling system

Liquid cooling

Coolant temperature

8085C, temporarily 90C allowed

Coolant filling quantity

96 l

Electrical equipment
Starter

24 V; 6.5 kW

Alternator

28 V; 55, 120, 225 A

61

Troubleshooting table
Fault
Engine does not start, or starts only with difficulty
Engine starts but does not reach full speed or stalls
Engine idles out of true when warm, misfiring
Engine speed fluctuates during operation
Power output unsatisfactory
Coolant temperature too high, coolant being lost
Lube oil pressure too low
Lube oil pressure too high
Black smoke accompanied by loss of power
Blue smoke
White smoke
Knocking in the engine
Engine too loud
Reason
D
Fuel tank empty
D
Fuel cock closed
D DDD
D
Air in fuel system
DD D D
D
Fuel pre-filter / pre-cleaner clogged
D
Condensation in fuel
DD
D
D
Air filter clogged
D
Electric circuit interrupted
D
Batteries flat
D
Starter / solenoid switch defective
D D
D D D Start of delivery not correct / incorrectly set
D
Injection nozzles clogged
D
Internal damage to engine
(piston seized, possibly caused by water in fuel)
D
D
D
Fuel quality not in accordance with specifications or fueled
severely contaminated
D
Lower idling speed set too low
D D
D D Valve clearance incorrect
D
Injection nozzles of injection pipes leaking
D
Too little fuel in tank
D
Rev. counter defective
D
D D
Injection nozzles defective or carbonized
D
Engine being asked to do more than it has to
D
Fuel supply faulty, fuel too warm
D
D
Oil level in sump too high
D
Incorrect rated speed setting
D
Coolant level too low
D
Air in coolant circuit
62

Troubleshooting table
Fault
Engine does not start, or starts only with difficulty
Engine starts but does not reach full speed or stalls
Engine idles out of true when warm, misfiring
Engine speed fluctuates during operation
Power output unsatisfactory
Coolant temperature too high, coolant being lost
Lube oil pressure too low
Lube oil pressure too high
Black smoke accompanied by loss of power
Blue smoke
White smoke
Knocking in the engine
Engine too loud
Reason
D
Tension of water-pump V-belts incorrect (slip)
D
Cap with working valves on expansion tank / radiator defective or leaking
D
Temperature gauge defective
D
Coolant pipes leaking, blocked or twisted
D
Oil level in sump too low
D
Engine temperature too high
D
Oil filter clogged
DD
Oil pressure gauge defective
DD
Selected oil viscosity not suitable for ambient temperature
(oil too thin)
D
Oil in sump too thin (mixed with condensation or fuel)
D
Engine cold
DD
Engine, coolant or intake air still to cold
D
Lube oil getting into combustion chamber
(piston worn, piston rings worn or broken)
D
Overpressure in crankcase (crankcase breather clogged)
D
long operation under a low load
D
Coolant getting into combustion chamber
(cylinder head / gasket leaking)
D Engine operating temperature incorrect
D Intake or exhaust pipe leaking

63

Index
A

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Maintenance and care . . . . . . . . . . . . . . . . . 4555

Bleeding the fuel system . . . . . . . . . . . . . . . . . . . 50

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operation monitoring

Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Display device MMDSL . . . . . . . . . . . . . . . . . . 26

Cleaning fuel precleaner . . . . . . . . . . . . . . . . . . 48

Display device MMDSLC . . . . . . . . . . . . . . . . 28

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Drive lever control system Mini Marex . . . . . . 36

Commissioning and operation . . . . . . . . . . . 1625

Engine room panel MMDSEP . . . . . . . . . . . . 35

Cooling system . . . . . . . . . . . . . . . . . . . . . . . 5153

Round instruments . . . . . . . . . . . . . . . . . . . . . . . 25
Operation monitoring system . . . . . . . . . . . . 2224

D
Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Draining the cooling system . . . . . . . . . . . . . . . . . 51

Raw water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Refilling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

E
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . 45

Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Safety regulations . . . . . . . . . . . . . . . . . . . . . . 1115

Handling used engine oil . . . . . . . . . . . . . . . . . . 14

Preventing accidents with injury to persons . . 11

Filling / bleeding the cooling system . . . . . . . . . . 52

Preventing damage to engine and premature

wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Filling with engine oil . . . . . . . . . . . . . . . . . . . . . . . 19

Filling with fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Preventing environmental damage . . . . . . . . . 14

Fillingin of coolant . . . . . . . . . . . . . . . . . . . . . . . . 18

Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

First commissioning . . . . . . . . . . . . . . . . . . . 1819

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2122

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Changing fuel filter . . . . . . . . . . . . . . . . . . . 49 , 50

Draining moisture . . . . . . . . . . . . . . . . . . . . . . . . 49

Technical data . . . . . . . . . . . . . . . . . . . . . . . . 5661

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 4850

Temporary decommissioning . . . . . . . . . . . . . . . . 55
Troubleshooting table . . . . . . . . . . . . . . . . . . 6263

I
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vbelts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5455

L
Lubrication system . . . . . . . . . . . . . . . . . . . . 4548

64

MAN Nutzfahrzeuge AG
Geschftseinheit Motoren
Vogelweiherstrae 33
D90441 Nrnberg
Ein Unternehmen der MAN Gruppe
Printed in Germany

51.995988498