MAN Nutzfahrzeuge AktiengesellschaftWartungsanleitung WA 74 (3.)
Dachauer Str. 667oderPostfach 50 06 20 Trucknology Generation A (TGA)
80995 MÜNCHEN80976 MÜNCHEN
–englisch–
Printed in Germany
Maintenance Manual
WA 74* (3.)
Trucknology Generation A (TGA)
81.99197– 4442
W
e reserve the right to make modifications in the course of further development. Due to the large number of
ypes, the figures in this Maintenance Manual are not always identical to the situation in your vehicle; they merel
resent a representation of one sample variant.
2003 MAN Nutzfahrzeuge Aktiengesellschaft
eprinting, copying or translation, even of extracts, is not allowed without written permission from MAN.
ll rights under the copyright law are strictly reserved by MAN.
SWD 5/Pfriemer Kataloge GmbH MünchenÜbersetzung + Satz: emes GmbH Druck: MAN–Werksdrucker
04.2003 – 0.23FriedrichshafenDocuTech
TABLE OF CONTENTS
MAINTENANCE INSTRUCTIONS
General instructions......................................................................................................................0.40 - 1
Fill quantities.................................................................................................................................0.70 - 3
Bleeding the fuel system............................................................................................................1.90 - 1
Bleeding the common-rail system..............................................................................................1.90 - 2
Main filter......................................................................................................................................1.90 - 3
Front axle steering knuckle...........................................................................................................3.10 - 1
End play........................................................................................................................................3.10 - 1
Drop arm nut.................................................................................................................................4.10 - 3
COMPRESSED AIR SYSTEM
Air dryer........................................................................................................................................5.10 - 1
Air dryer granulate cartridge.........................................................................................................5.10 - 2
General information......................................................................................................................9.00 - 1
Menu structure...........................................................................................................................9.00 - 2
Baseline
General instructions...................................................................................................................9.01 - 1
Calling up and exiting the menu.................................................................................................9.01 - 2
Scanning scheduled service dates.............................................................................................9.01 - 3
Setting the forewarning for scheduled service dates .................................................................9.01 - 4
Indications on driver's display and panel of check lamps ..........................................................9.01 - 7
0.30 - 6WA 74 (3rd)
TABLE OF CONTENTS
Highline
General instructions ...................................................................................................................9.02 - 1
Calling up and exiting the menu.................................................................................................9.02 - 1
Scanning scheduled service dates.............................................................................................9.02 - 2
Setting the forewarning for scheduled service dates..................................................................9.02 - 3
Indications on driver's display and panel of check lamps...........................................................9.02 - 6
WA 74 (3rd)0.30 - 7
T
he
Maintenance Manual
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MAINTENANCE WORK
Checking correct functioning
• Check that the equipment, unit or device is in an
operational condition
• The functional check also includes a test drive
Checking the setting/play
• Measure the actual value. Check whether the
actual value is within the specified tolerance band.
Repair or renew the component concerned if it is
out of tolerance.
Checking for wear
• Determine the degree of wear. Repair or renew
the component concerned if the wear limit
indicated has been reached.
Checking condition
• Check the appearance of the object, e.g. by
looking for leaks, rust, cracks, pitting, deformation,
damage and dirt
Checking firm seating
• Check fastenings and connections for signs of
loosened screws or bolts, e.g. cracks in the paint,
truncations and rust
• Tighten any screw or bolt connections which have
become loose
• Check that slotted/castellated nuts have their
locking elements fitted
• If the locking element has come loose or is
missing, unscrew the slotted/castellated nut and
tighten it again. Fit a new cotter pin and, if
necessary, apply marking paint
• Fit new self-locking connections if the old ones
have come loose or are damaged. Tighten the
new connections and, if necessary, apply marking
paint
Checking for leaks
• Check housing joins, lines and connections
• Tighten any connections which have come loose
• Depressurise the system before re-tightening a
leaking screwed connection
• Immediately fit new hydraulic hoses if you notice
damage or porosity on the old ones
• Immediately repair major leaks involving
continuous oil or fluid loss
MAINTENANCE INSTRUCTIONS
aintenance type and a description of maintenance
ork. For details of special bodies and attachments
s well as additional equipment, please refer to the
ervice documentation provided by the manufacture
oncerned.
aintenance work must be carried out properly and
t the specified intervals in order to ensure constan
ehicle availability, road safety and a long vehicle
ervice life. Recommended maintenance work whic
equires specialist knowledge may only be carried
ut by qualified personnel.
ou will find a detailed explanation of the MAN
aintenance system and the intervals at which the
arious services are due, depending on the
aintenance group, in the current "Maintenance
ecommendations and Recommended Service
roducts" booklet.
onfirmation that maintenance work has been
erformed correctly and at the specified intervals is
o be entered in the "Maintenance Record" together
ith the relevant details.
n the event of claims under warranty, evidence mus
e brought that proper maintenance was carried ou
t the specified intervals, that approved or
ecommended service products were used and that
enuine MAN spare parts were installed.
herefore, we would ask
he vehicle owner
to always have the maintenance work carried
out only in authorised service centres and
he staff of the service centres
to follow the instructions and
recommendations given in this Maintenance
Manual.
ENERAL INSTRUCTIONS
• Always fit new seals and gaskets to replace ones
that have worked loose
ote: Non-damaged valve cover and intake seals
made from aluminium/elastomers can be
reused.
includes details of the
• Use a torque wrench to tighten connections for
which a tightening torque has been specified
• Clean removed parts before refitting them. Check
them for damage if the instructions do not
recommend that you should renew them
• Fit new hose lines if the outer jacket is damaged o
has become brittle. This also applies if the hose
fittings are damaged or if the hose is coming out o
its fittings
• The specialist staff responsible must determine th
cause of malfunctions, incorrect settings and
damage, even if the rectification of such problems
does not form part of the maintenance work
WA 74 (3rd)0.40 - 1
Lubricating
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Checking oil and fluid levels
• Park the vehicle on a flat, level surface
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MAINTENANCE INSTRUCTIONS
• Check the engine oil level with the engine cold if
possible. However, always wait at least 15 minute
after stopping the engine (deviations between
measurements with the engine hot and cold are
possible and to be expected). The only reliable
method of establishing the oil level is with the
engine cold after the vehicle has been parked on
flat, level surface for several hours.
• Do not top up the engine oil until the oil level has
fallen to the bottom "MIN" mark on the dipstick.
Never top up with oil so the level exceeds the
"MAX" mark. This merely causes oil to be pumpe
through the engine vents and is uneconomical.
• If a retarder and automatic gearbox are fitted,
perform the main oil level check at operating
temperature.
Refer to the instructions in the work descriptions!
• Do not check the oil level in the manual gearbox
and driven axle immediately after completing a
journey. Wait until the gearbox oil has cooled dow
• If you can see that a unit is losing oil or fluid, chec
the unit in question frequently and determine the
cause of the leak
hanging oil and fluid
• Park the vehicle on a flat, level surface
• Drain the oil whilst it is warm
• Use a suitable container to collect the escaping o
or fluid
• Clean the screw plugs and fit new seals
• Do not use contaminated service products
• The decisive factors in obtaining the exact oil
quantity are correctly filling the oil and properly
performing the subsequent oil level check
• The specified fill quantities apply to oil or fluid
changes and not to complete refills, e.g. after
maintenance work
• Clean the lubrication points before lubricating, if
necessary
• Clean the lubricating nipples before lubricating
• Fit new lubricating nipples if the existing ones are
damaged
• Wipe off excess grease after lubricating
pecial points in the text
Refers to working and operating
procedures which must be followed
exactly so as not to endanger service
personnel and in order to avoid general
damage or irreparable damage to the
vehicle and its components.
ote about work descriptions
nits and systems may be installed in many
ifferent configurations. Consequently, it is not
lways possible to illustrate the exact surroundings
f the working area.
0.40 - 2WA 74 (3rd)
NOTES ON SAFETY
A
lways secure the vehicle to prevent it from
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Cleaning
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NOTES ON SAFETY AND ENVIRONMENTAL PROTECTION
olling away before starting any maintenance
ork:
• Apply the parking brake and, if necessary, use
wheel chocks (applying the retarder does not hold
the vehicle when it is parked)
• Power-actuated parts and attachments must be
secured against unintended movement
hen the cab is tilted:
• Keep the area around the cab clear
• No-one is allowed to be between the cab and the
chassis whilst the cab is being tilted
• Never lean on the vehicle whilst the cab is being
tilted
• Always tilt the cab forwards past the tilting point to
its final position
• Use the door arrester when the cab is tilted with
the door open
efore starting the engine:
• Apply the parking brake and shift the gearbox to
neutral
aintenance work when the engine is running:
• Parts of the engine, cooling system and gearbox
become hot during operation – risk of burns
• Do not touch any rotating parts on the free ends o
shafts, keep your distance, watch out for rotating
fans
• Ensure adequate ventilation if you are working in
enclosed spaces
hen changing oil or fluid:
• Note the temperature of the oil or fluid – if it is hot
from operation there is a risk of burns
• Carefully open caps if the systems and
components are pressurised
• Do not change oil or fluid whilst the engine is
running
Danger of accidents!
Refer to the Operator's Manual for tilting
and lowering the cab!
Danger of accidents!
Danger of accidents when starting the
engine with a gear engaged!
Danger to life!
Stop the engine and switch off the
ignition before washing the vehicle if
the vehicle has a high-voltage (above
24 V) electrical system.
• Do not use inflammable liquids or toxic
substances for cleaning
• Vacuum up the dust from cleaning wheel brakes
or wet it, collect it and dispose of it
onnecting up/disconnecting at measuring an
est connections:
• Only when the engine is switched off and the
measuring point is depressurised
aising and jacking up the vehicle:
• Locate the jack or support at the designated
jacking points so that it cannot slip
• Do not start to work under the raised vehicle un
it has been secured against rolling or sliding
away, tipping over or dropping
f the vehicle has ECAS:
• Do not switch on the ignition whilst the vehicle is
raised as this will activate the level control
system
• After switching the ignition off, wait for up to
10 minutes before raising the vehicle
topping the engine in emergencies (only whe
ehicle is at a standstill):
• Apply the parking brake
• Engage a high gear
• Apply the service brakes and, taking great care
slowly engage the clutch and stall the engine (n
possible with an automatic gearbox) or activate
the emergency off switch (special equipment)
ervice products
• Avoid unnecessary contact with service product
• Do not inhale harmful gases and vapours
• Wear a breathing mask or use an extractor whe
working in a dusty environment
WA 74 (3rd)0.50 - 1
Electrical system
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Air-conditioning system
t
NOTES ON SAFETY AND ENVIRONMENTAL PROTECTION
Health risk!
• Avoid any contact with them!
• Wear protective glasses and gloves!
Obtain immediate medical assistance from a
doctor if refrigerant contacts your skin or gets into
your eyes.
• Do not drain gaseous refrigerants in enclosed
areas. Danger of suffocation!
• Pump out refrigerants using a disposal system!
• Never perform soldering or welding work, etc. on
parts of the system or near to it, even if the
refrigerant has been drained. Danger of explosion
and intoxication!
• Do not clean parts of the system using a steam
cleaner!
• Always have work on the refrigerant circuit
performed in an authorised MAN Service
workshop!
• The use of propane-butane refrigerants in MAN
vehicles is prohibited
• The air-conditioning system is filled with CFC-free
refrigerant R 134a
• Please observe national regulations in non-EU
countries
Refrigerant fluids and vapours represen
a health hazard!
hen carrying out maintenance on batteries:
• Batteries contain corrosive acid, so be careful
when touching them
• Avoid short-circuits
• Charging batteries gives rise to an explosive
oxyhydrogen gas mixture. Do not use naked
flames
f the engine is running:
• Do not undo/remove any connection cables on
the alternator or any battery terminal posts
• Do not disconnect the battery master switch
f using an external power source:
• 220 V consumers (external power source) are
only allowed to be connected to the vehicle via
overcurrent circuit breakers in the building
heel nuts
• In new vehicles/after changing a wheel, retighte
the wheel nuts after driving approx. 50 km, then
check them every day to make sure they are
firmly seated and have the correct tightening
torque. Retighten them if necessary. Continue
doing this until final tightness is assured
pecial bodies and attachments
f the vehicle has a special body or attachment,
omply with the notes on safety provided by the
elevant manufacturer. For further action to be
aken, consult the general accident prevention
egulations.
imited liability for accessories
n your own interests, you are recommended to
se only accessories expressly approved by MAN
nd genuine MAN parts.
he reliability, safety and suitability of these parts
nd accessories have been determined specifical
or MAN vehicles. Despite constant market
bservation, we cannot judge the aspects of other
roducts, nor can we accept responsibility for them
even if they have been approved or authorised
y an official body.
0.50 - 2WA 74 (3rd)
ENVIRONMENTAL PROTECTION
U
sed oil (engine oil, gearbox oil, etc.)
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Coolant
Treat undiluted antifreeze as hazardous waste.
Follow the instructions issued by the relevant local
authority when disposing of used coolant (mixture
of antifreeze and water).
Starter batteries (applicable to the EU)
Starter batteries contain pollutants; they must
therefore be returned to the manufacturer to be
correctly disposed of. Vendors of starter batteries
(dealers) are obliged to charge a deposit which is
refunded when the battery is returned.
Never dispose of used batteries in the
domestic refuse!
Please observe the national regulations in non-EU
countries.
Cleaning the vehicle
• Use detergents which do not affect the
groundwater
• Wash the vehicle over an oil separator
• The use of high-pressure cleaners is prohibited
on and around all lubrication points
NOTES ON SAFETY AND ENVIRONMENTAL PROTECTION
herefore, never pour used oil onto the ground, into
ater or down the drains or sewers. Failure to
omply with these instructions can lead to
Take care to dispose of used engine oil
properly.
Used engine oil can damage
groundwater quality.
rosecution.
ollect and dispose of used oil carefully. Contact th
oint of sale, supplier or your local authority for
nformation about collection depots.
xtract from "Information on dealing with used
ngine oil", The Mineral Oil Traders' Association
MINERALÖLWIRTSCHAFTSVERBAND e.V.),
teindamm 71, D–20099 Hamburg)
ilter cartridges, elements and box-type filters,
esiccant cartridges
ilter elements, cartridges and box-type filters (oil
nd fuel filters, desiccant cartridges for the air dryer
re classified as hazardous waste materials and
ust be disposed of properly.
lease follow the instructions issued by the relevant
ocal authority.
WA 74 (3rd)0.50 - 3
TGA TRUCKS
Job no.
Acceptance date
Service consultant signature
Tick oil changes
Enter oil
specification
Tick service
Enter estimated remaining life
Brake
Clutch
Omitted if the statutory safety
General technical safety
Brake technical safety
Miscellaneous
Torque converter/
clutch system (WSK)
Tick additional work that is due every time the
Tick service
After max.
kmYears
Renew air dryer desiccant
cartridge
o
ZF 16 S gearbox with Intarder
Renew air filter element
o
ZF ASTRONIC gearbox with Intarder
Change coolant and renew
pressure-relief valve
o
Eaton 8309 gearbox
1st steering inspection
Steering on front axle(s)
500,000
4
o
ZF 5/6 HP 500/600 automatic gearbox
Steering on rear axle
500,000
4
o
Axle/gearbox with 500,000 km interval
Each subsequent steering
inspection
o
Torque converter/clutch system (WSK)
Perform a brief test drive and check the brakes after
Air inlet, heating/ventilation/air-conditioning system: Dust filter (renew more often if dirt build-up is
Check that the lubrication points connected to the central lubrication system are
2)
3)
4)
OPERATION-SPECIFIC WORK
SYSTEM DIAGNOSIS:
Read out fault memory (using MAN-cats II)
Read out the remaining brake and clutch life (using MAN-cats II)
CHECKING AND ADJUSTMENT WORK:
Retighten cylinder head bolts (for D28 engine with bolts tightened by angle)
Minimum mileage 1,000 km, maximum 20,000 km
Retighten pressure flange collar nut for nozzle holder (for D28 4-valve engine)
Check valve clearance and adjust if necessary
Poly-V-belts: Check condition
Air dryer: If there is water in the air tank, drain it off and fit a new desiccant cartridge
Air-conditioning system: Check refrigerant level and dryer, refill and fit new dryer if necessary
CHECK: Fluid level
Gearbox
Torque converter and clutch system (WSK), separate oil circuit
Transfer case
Power take-off NMV
Driven axle(s)
Hydraulic pump, cab tilt mechanism
Air-conditioning system, refrigerant
RENEW:
3)
2)
1)
1)
3)
ES 6S 12
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heavy)
Auxiliary air and/or water heater: Fuel supply filter
correctly supplied.
Lubricate those lubrication points not connected to the central lubrication system.
Trailer/fifth wheel coupling
Spare wheel hoist cable
Tipper body: Bearing points
Central lubrication system: Lubricant reservoir and lubricant supply
Brake camshaft (planetary axle with drum brake)
Slack adjuster (planetary axle with drum brake)
Supporting structure for swap body: Main bearing journal thread, centring roller support
Cab tilt mechanism: Locking mechanism
Oil change, ZF NMV power take-off with oil filter
Oil change, tipper hydraulics (first oil change after approx. 1500 tipping operations)
1)
Omitted in the case of common-rail engine D2876 LF 12/13 and D0836 LF 41/44
Omitted during first service in the case of all D28 engines
Have refrigerant topped up or have refrigerant changed and new dryer fitted (by a refrigerant expert only)
For vehicles without central lubrication system only
4)
4)
4)
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0.60 - 2WA 74 (3rd)
MAN ProFit-CheckTGA Trucks
May be omitted if maintenance and statutory safety inspection are performed by MAN Service
Check steering system, incl. sealing bellows on ball joints
Trailing axle steering
Leading axle steering
Check air suspension system for cracks, particularly rolling air bellows
Trailer/fifth wheel coupling and fifth wheel plate
Steering knuckles, also check end play
CHECK: Firm seating, secureness
ES 6S 12
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Wheel nuts (observe tightening torque)
Spring U-bolts, spring mounting bolts
Steering, steering linkage, drop arm nut, steering mounting
Spare wheel bracket and mounting
Roof spoiler/aeropackage/supporting structure
at the same time.
CHECK: Brake system
wear, functional check (including slack adjuster) and effectiveness test
PREVENTIVE INSPECTION
chafing
water cooler and intercooler
Cable connections, fastenings and routing: Battery, starter, alternator, earthing point
Cab: Tilting and locking mechanism, hydraulic system
Intake/exhaust system/exhaust gas recirculation system
Fuel system, incl. auxiliary air and/or water heater
Locking function, steering/starter lock
Tipper system
Central lubrication pump setting
Cab mounts, incl. air suspension
Propshaft
Air-conditioning system: Equipment fixtures, refrigerant line ports
Leaf suspension: Check that intermediate rubber layer is fitted
CHECK: Firm seating, secureness
Nuts and bolts: Engine, gearbox, axles, chassis, body mounting
Retighten cooling system hose clamps (omitted in the case of spring clamps in the charge air area)
Trailer/fifth wheel coupling and fifth wheel plate
1)
Must be checked by refrigerant expert
1)
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WA 74 (3rd)0.60 - 3
MAN ProFit-CheckTGA Trucks
WINTER SERVICE
Type
Retighten cylinder head bolts (for D28 engine with bolts tightened by angle)
CHECKS AND MINOR MAINTENANCE JOBS
CHECK: Fluid level
Engine oil (dipstick)
Hydraulic power steering (dipstick)
Hydraulic trailing axle steering (dipstick)
Cooling/heating system, incl. min. antifreeze/anti-corrosion protection concentration (level in tank)
Hydraulic clutch and gear shift actuator (level in tank)
Top up windscreen washers and headlight cleaning system
Batteries
CHECK: Display
Engine oil level: Read off from display
Remaining brake/clutch life: Read off date or mileage/km from display
Fault memory: Read off entries from display
Tyres: Condition and inflation pressure, including spare wheel
1)
Omitted if data has been read out using MAN-cats II
1)
1)
T
Windscreen washers, headlight cleaning system: Add antifreeze
Cooling and heating system: Check antifreeze and top up if necessary
Check headlights and adjust if necessary
Lubricate door lock cylinders (spray 09.15014-0024)
Check correct functioning and condition of auxiliary air and/or water heater
Check function and condition of traction chain
Batteries: Check acid strength
ES 6S 12
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Maintenance work forreconditioned engine (E service only): Maintenance work for the reconditioned
engine is integrated in the normal maintenance rhythm of the vehicle after this maintenance work has been performed.
Engine
Clutch
Intake/exhaust system
Cooling and heating system
Fuel system
Cable connections and fixtures: Battery, starter, alternator, earthing point
Steering system
CHECK: Firm seating, secureness
Nuts and bolts: Engine
Retighten cooling system hose clamps (omitted in the case of spring clamps in the charge air area)
CHECKING AND ADJUSTMENT WORK:
Minimum mileage 1,000 km, maximum 20,000 km
Retighten pressure flange collar nut for nozzle holder (for D28 4-valve engine)
Check valve clearance and adjust if necessary
CHANGE OIL
Engine, also change filter
LUBRICATE USING AN OIL CAN OR GREASE: Linkages, cables, joints, bearings, hinges
1)
Omitted in the case of common-rail engine D2876 LF 12/13 and D0836 LF 41/44
2)
Omitted during first service in the case of all D28 engines
2)
1)
E (A)
0.60 - 4WA 74 (3rd)
TECHNICAL DATA
TECHNICAL DATA
)
D0836 LF
41
D0836 LF
44
D2876 LF
12
D2876 LF
13
Rated output 1) (KW/hp)
at engine speed (rpm)
206/280
2400
240/326
2400
353/480
1900
390/530
1900
Peak torque (Nm)
at engine speed (rpm)
1100
1200-1750
1250
1200-1800
2300
1000-1300
2400
1000-1400
Valve clearance with engine cold (mm):
Intake valve bridge/rocker arm
Exahust valve bridge/rocker arm
Exhaust valve bridge/EVB counter-holder
0.50
0.50
0.50/0.35
0.50
0.60
0.40
Oil pressure with engine at operating
temperature (bar):
At idling speed
At rated engine speed
Operating limit at idling speed
1.2-1.5
4.0-5.0
1.0
D2866 LF
26
D2866 LF
27
D2866 LF
28
D2876 LF
04
D2876 LF
05
Rated output 1) (KW/hp)
at engine speed (rpm)
228/310
1800-1900
265/360
1800-1900
301/410
1900
338/460
1700-1900
375/510
1900
Peak torque (Nm)
at engine speed (rpm)
1500
900-1300
1700
900-1400
1850
900-1300
2100
900-1300
2300
1000-1300
Valve clearance with engine cold (mm):
Intake valve bridge/rocker arm
Exahust valve bridge/rocker arm
Exhaust valve bridge/EVB counter-holder
0.50
0.60
0.40
Oil pressure with engine at operating
temperature (bar):
At idling speed
At rated engine speed
Operating limit at idling speed
1.2-1.5
4.0-5.0
1.0
D2866 LF
36
D2866 LF
37
D2866 LF
32
D2876 LF
07
Rated output 1) (KW/hp)
at engine speed (rpm)
228/310
1700-1900
265/360
1800-1900
301/410
1800-1900
338/460
1800-1900
Peak torque (Nm)
at engine speed (rpm)
1500
900-1300
1700
900-1300
1850
900-1300
2100
900-1300
Valve clearance with engine cold (mm):
Intake valve bridge/rocker arm
Exahust valve bridge/rocker arm
Exhaust valve bridge/EVB counter-holder
0.50
0.60
0.40
Oil pressure with engine at operating
temperature (bar):
At idling speed
At rated engine speed
Operating limit at idling speed
1.2-1.5
4.0-5.0
1.0
1)
ENGINES
Engine model – common rail (EURO 3
Firing sequence1–5–3–6–2–4
Engine model (EURO 3)
Firing sequence1–5–3–6–2–4
Engine model (EURO 2)
Firing sequence1–5–3–6–2–4
to ISO 1585–88/195 EEC
WA 74 (3rd)0.70 - 1
TECHNICAL DATA
POLY-V BELTS
V-belt tension.................................Set using gauge
Note: Always use brake pads of the same quality on
front and rear axle(s).
Brake pad wear limit.....................................4 mm
Note: The warning limit is:
4 mm remaining pad per pad. The "brake
pads" indication is on the driver's display,
see Operator's Manual.
The absolute wear limit is:
2 mm – renew the brake pads immediately!
Brake disc wear limit..................................37 mm
≤
ear axle
Y – 1350.....Driven hypoid axle with twin tyres,
with and without transverse lock
P – 1352.....Driven planetary axle with twin tyres,
with and without transverse lock
PD – 1382...Through-drive planetary axle with tw
tyres, with and without transverse loc
9 – ..............Planetary axle (AP) with twin tyres,
with and without transverse lock
D9 – ...........Planetary axle (AP) with tandem axle
and interaxle differential lock in powe
divider on 1st rear axle
Drum brake
Brake lining thickness (wear limit)
................................................................min. 5 mm
Clearance between lining and brake drum,
gap...............................................................0.7 mm
0.70 - 2WA 74 (3rd)
TECHNICAL DATA
Front axle
VA 9 – 0950........................................................9.2
Centre drive.....................................................6.0
Planetary drive........................................... 2 x 1.5
Steering knuckle......................................2 x 0.05
Air-conditioning system...............approx. 0.95 kg
FILL QUANTITIES
(approx. change quantities in
l
T
t
o
c
F
C
E
C
w
w
w
d
R
H
H
H
H
H
H
itres)
he most accurate method of establishing the exac
il or fluid fill quantity always involves filling the unit
orrectly and properly checking the oil or fluid level.
ir-conditioning system...............approx. 0.95 kg
ULBS (24 V)
eadlights (H7)
Headlight low beam .....................................70 W
Headlight high beam.................................... 70 W
Parking lights .................................................4 W
urn indicators................................................ 21 W
rake lamps.................................................... 21 W
ail lights......................................................... 10 W
arker lights ..................................................... 5 W
og lamps/additional high-beam
headlights (H3).............................................. 70 W
riority vehicle light......................................... 70 W
eversing lights .............................................. 21 W
river's area ceiling lights................... 21 and 10 W
ntry lights........................................................ 5 W
utline lights..................................................... 5 W
nterior lighting, bunks............... (12V) 6 W (Sofitte)
as discharge (special equipment) ..................D2R
ide marker light (SML)....................................LED
0.70 - 4WA 74 (3rd)
TYRES AND INFLATION PRESSURE
A
ll the vehicle's tyres must correspond to the entry in the vehicle’s registration certificate/data sheet
(
T
A
T
1
1
1
2
2
3
3
3
2
3
3
2
3
T
A
T
1
1
1
2
2
3
3
3
2
3
3
2
3
TECHNICAL DATA
size, speed index, load index).
Always refer to the documentation provided by the tyre manufacturer for the exact tyre
2 R 22,57.57.57.757.758.08.08.5––––
3 R 22,5 / K6.56.756.757.07.07.257.58.0–––
3 R 22,5 / L6.56.756.757.07.07.07.58.08.5––
85/60 R 22,59.0––––––––––
95/60 R 22,58.759.09.0––––––––
05/60 R 22,58.58.58.758.759.0––––––
15/60 R 22,58.08.08.08.258.258.259.0––––
85/65 R 22,5–––6.56.56.757.07.58.08.59.0
75/70 R 22,59.0––––––––––
05/70 R 22,58.08.08.258.258.5––––––
15/70 R 22,57.57.57.757.758.08.258.59.0–––
95/80 R 22,57.57.57.757.758.08.258.5––––
15/80 R 22,57.07.257.257.57.57.758.08.5–––
2 R 22,55.75 6.256.757.257.57.758.0–
3 R 22,5 / K–5.55.756.56.756.757.257.75
3 R 22,5 / L5.55.756.256.757.07.257.58.25
85/60 R 22,5–7.07.58.08.258.59.0–
95/60 R 22,5–7.07.58.258.58.59.0–
05/60 R 22,5––7.258.08.258.258.5–
15/60 R 22,5–––7.257.57.758.0–
85/65 R 22,5––––––––
75/70 R 22,5––7.758.08.258.5––
05/70 R 22,5––6.57.07.257.57.75–
15/70 R 22,5–––6.757.07.257.58.25
95/80 R 22,5––6.57.257.57.758.0–
15/80 R 22,5–––6.56.56.757.07.75
inflation pressures!
The tyre inflation pressure charts below only indicate an overview of the tyre inflation
pressures.
yre inflation pressure (in bar with tyres cold)Single tyres
on gearbox....................................................4 – 5
on axle..........................................................4 – 5
on breather...................................................4 – 5
or further details regarding tightening torques,
efer to Works Standard M 3059, relevant Repair
anual or brochure "SD 200".
WA 74 (3rd)0.70 - 7
REFERENCE TORQUES
Tightening torques to Works Standard M 3059
Strength classes
(bolt/nut) in Nm
Nominal thread size x pitch
8.8/8
10.9/10
12.9/12
M 4
2.5
4.0
4.5
M 5
5.0
7.5
9.0
M 6
9.0
13.0
15.0
M 7
14.0
20.0
25.0
M 8
22.0
30.0
35.0
M 8 x 1
23.0
35.0
40.0
M 10
45.0
65.0
75.0
M 10 x 1.25
45.0
65.0
75.0
M 10 x 1
50.0
70.0
85.0
M 12
75.0
105.0
125.0
M 12 x 1.5
75.0
110.0
130.0
M 12 x 1.25
80.0
115.0
135.0
M 14
115.0
170.0
200.0
M 14 x 1.5
125.0
185.0
215.0
M 16
180.0
260.0
310.0
M 16 x 1.5
190.0
280.0
330.0
M 18
260.0
370.0
430.0
M 18 x 2
270.0
390.0
450.0
M 18 x 1.5
290.0
410.0
480.0
M 20
360.0
520.0
600.0
M 20 x 2
380.0
540.0
630.0
M 20 x 1.5
400.0
570.0
670.0
M 22
490.0
700.0
820.0
M 22 x 2
510.0
730.0
860.0
M 22 x 1.5
540.0
770.0
900.0
M 24
620.0
890.0
1040.0
M 24 x 2
680.0
960.0
1130.0
M 24 x 1.5
740.0
1030.0
1220.0
With the exception of subordinate or tacking connections, screw connections without specially prescribed
tightening torques should always be tightened using standard workshop torque wrenches or precision nut
runners.
The tightening torques applied should not differ from the specified settings by more than ±15%.
Note on using the tables
− For strength pairings other than those given, use the tightening torque for the part in the lower strength
class (e.g. bolt in strength class 8.8, nut in strength class 10; the tightening torque is determined from the
8.8/8 column).
− When tightening a part with a slot onto a part with a round hole, work from the side with the round hole.
− − Important note regarding collars with ribbed head contact surface (e.g. Verbus Ripp):
∗ Wherever possible, always tighten (to the applicable torque for the component concerned) on the side
of the harder material when tightening soft components against hard ones.
∗ Only use ribbed locking bolts in conjunction with steel washers on slots or components made from
light alloy.
∗ When re-assembling (e.g. following repairs), always use new bolts or nuts on the tightening side.
∗ When tightening galvanised ribbed locking bolts onto components made from nodular cast iron (GGG)
or from less hard materials, increase the settings indicated by approx. 15%.
− Under certain circumstances (e.g. unfavourable surface pairing with very low coefficient of friction), the
bolt may tear or the nut thread may be damaged when tightening galvanised bolts. In such cases, reduce
the tightening torque as necessary; however, the tightening torque must not be below 85% of the
reference value.
Bolts/nuts with external or internal hexagon heads, collarless or flangeless head:
cast iron (GG, GTS) as well as for nodular cast iron (GGG) for diameter M 12 or less.
2)
Value for tightening onto less hard component materials such as chassis and chassis attachments
(QSTE 340, QSTE 420, ST 2 K 60) and soft component materials such as body panels (ST 12, ST 13,
ST 14), attachments made of ST 37 as well as for nodular cast iron (GGG) for diameter M 14 or greater.
3)
When tightening galvanised ribbed locking bolts/nuts onto nodular cast iron, the values for tightening
onto harder component materials always apply.
4)
Applies to ribbed locking bolts (serrated) only
WA 74 (3rd)0.70 - 9
REFERENCE TORQUES
Table from Works Standard M3059–1
FK 10.9/10
FK 10.9/10
FK 12.9/12
FK 10.9/10
Thread size
Preload
force
Dacromet (silver–
grey/bluish1))
Galvanised (yellow)
Phosphated (black)
Phospha-
ted (black)
F
V max
[kN]
Material group
1 (hard)
2 (soft)
1 (hard)
2 (soft)
1 (hard)
2 (soft)
M 510811811–
–
Special
M 61414191419––design.
M 82633453345––Values
M 104170957095––currently
M 1270––––150
170
not
M 12 x 1.5
66
110
137
120
150––
defined
M 1496––––260
320
M 14 x 1.5
95,5
200
310
210
280––
M 16
132––––
360
425
M 16 x 1.5
129
290
380
270
370––
M 18 x 2
174
To be determined or indicated in the
520 2)520
2)
M 18 x 1.5
187
technical documents
550 2)550
2)
Nominal assembly tightening torques M
[Nm] and preload forces FV [kN] for connections with ribbed
A
(Rippen type) or toothed (Durlok type, for M18 thread sizes only) contact surface with flange head or collar.
Desired total coefficient of friction µ
1)
Bluish colour, for the purpose of indicating sliding compound treatment to MAN 183
2)
Values apply to Durlok version only
total
= 0.11
0.70 - 10WA 74 (3rd)
ENGINE / CYLINDER HEAD BOLTS
ENGINE (D2866 LF 26, 27, 28, 32, 36, 37;
6
4
3
2
1
51.97801-0212
1
4
2
5
3
Exhaust end
D2876 LF 04, 05, 07;
CYLINDER HEAD BOLTS
Retightening cylinder head bolts in accordance
with the tightening diagram
The 2nd retightening shown here is part of the first
service (E).
− Do not loosen the cylinder head bolts beforehand
− Only retighten the four bolts indicated
− The engine temperature is not important
• Stop the engine
• Tilt the cab
• Retighten the cylinder head bolts by 90° (¼ turn)
in accordance with the tightening diagram
1, 2
(sequence
, 3, 4)
• Then check the valve clearance and adjust it if
necessary
• After retightening the cylinder head bolts, remove
the old adhesive label (MAN no. 51.97801-0211)
and, in its place, affix the adhesive label containing
the text opposite (MAN no. 51.97801-0212)
• Lower the cab
Zweiter Nachzug der Zylinder-
kopfschrauben erledigt
Second retightening of
cylinder-head-bolts completed
D28 ENGINE – retightening for newly delivered
vehicles or new and reconditioned engines
Distinguishing feature:No "First retightening of
cylinder head bolts completed" adhesive label on
one of the valve covers.
In the case of the engines with modified cylinder
liners, first retightening of the cylinder head bolts no
longer takes place at the factory.
The "First retightening of cylinder head bolts
completed" adhesive label is therefore omitted.
However, the cylinder head bolts must be
retightened during the next appropriate service, after
1000 km at the earliest and after 45,000 km at the
latest. Also see Service Information "124000 – D28
cylinder head" dated 10.03.2003.
• Retighten the bolts tightened by angle by 90°
(¼ turn), without loosening them, in accordance
1
6
with the tightening diagram (sequence
to
)
See figure on the right for tightening diagram.
WA 74 (3rd)1.00 - 1
ENGINE / CYLINDER HEAD BOLTS
After retightening is complete:
51.97801-0315
51.97801-0316
• Affix adhesive label MAN no. 51.97801-0315
(German/English) onto one of the valve covers
or
• Affix adhesive label MAN no. 51.97801-0316
(French/Spanish) onto one of the valve covers
Nachzug der Zylinder-
kopfschrauben erledigt
Retightening of
cylinder-head-bolts completed
Resserage des vis de
culasses effectué confromément
Rapriete de los tornillos
de culata efectuado
1.00 - 2WA 74 (3rd)
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITHOUT EVB
D2866 LF 26/27/28/32/36/37
1
231
2
D2876 LF 04/05/07/12/13
FOUR-VALVE – WITHOUT EVB
Engines with 4-valve cylinder heads without EVB
are indicated by the plate opposite on one of the
valve covers.
VALVE CLEARANCE
Checking (engine no more than lukewarm)
• Stop the engine
• Tilt the cab
Fitting the engine barring gear
• Remove the cover from the flywheel housing
• Fit the engine barring gear, MAN no.
80.99626-6008
This engine barring gear allows the flywheel to be
1
blocked with pin
2
or 3.
in the desired position using hole
• Attach the gear ratchet, MAN no. 80.99627-0001
Ventilspiel / Valve Lash
Einlass / Intake0.5 mm
Auslass / Exhaust0.6 mm
Removing the cylinder head cover
• Unscrew and remove the mounting bolts
• Remove the cylinder head cover and the cylinder
head cover gasket
Note (D2866 LF 26/27/28/32/36/37
D2876 LF 04/05/07):
1
Handle the gasket
connecting cable
sensor
(NBF) with care.
at the passage for the
2
for the needle movement
WA 74 (3rd)1.10 - 1
ENGINE D 2866 LF, D 2876 LF,FOUR-VALVE – WITHOUT EVB
Note (D2876 LF 12/13):
Rocker arm in overlap on
cylinder:
15362
4
Rocker arm relieved, check/
adjust valve clearance on
cylinder:
62415
3
123456
2
112
Handle the injector cable passage (à) with
care.
Cylinder order and valve arrangement
− Cylinder order: 1 to 6
− Firing sequence: 1 – 5 – 3 – 6 – 2 – 4
− The 1st cylinder is at the fan end.
1 Fan end
2 Gearbox end (power output)
Intake valves
Exhaust valves
• Move the piston of the cylinder requiring
adjustment to ignition TDC. To do this:
Use the engine barring gear to turn the flywheel
until the rocker arms on the cylinder concerned
have been relieved; the flywheel can be blocked in
this position.
The rocker arms of the synchronous cylinder are
then in overlap.
The two intake valves are actuated by a rocker arm
1
via a bridge
2
as are the two exhaust valves.
Desired valve clearance:
Intake valve bridge/rocker arm...............0.50 mm
Exhaust valve bridge/rocker arm............0.60 mm
1
• Insert a feeler gauge between rocker arm
bridge
2
and
You must be able to move the feeler gauge with little
resistance.
Adjust the valve clearance if the desired value is not
obtained.
1.10 - 2WA 74 (3rd)
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITHOUT EVB
Adjusting (with the engine cold)
124
1
2
3
The piston of the cylinder which requires adjustment
must be at ignition TDC.
Note: Use valve setting key to adjust the valves.
1 Torque wrench
MAN no. 08.06450-0006
2 Valve setting key WAF 14
MAN no. 08.06455-0029
3 Valve setting key WAF 21
MAN no. 08.06455-0030
4 Hexagon socket screw wrench
MAN no. 08.06125-9035
• Undo the lock nut on the rocker arm using
the valve setting key
Desired valve clearance:
Intake valve bridge/rocker arm................ 0.50 mm
Exhaust valve bridge/rocker arm ............0.60 mm
• Use valve setting key to turn the adjuster screw
until the feeler gauge can be moved between the
rocker arm and the bridge with little resistance
• Fit the cylinder head cover gasket (elastomer) onto
the cylinder head cover
• Fit the cylinder head cover
Note (D2866 LF 26/27/28/32/36/37
D2876 LF 04/05/07):
1
Ensure that the gasket
the connecting cable
movement sensor
at the passage for
2
for the needle
(NBF) is seated correctly.
Note (D2876 LF 12/13):
Ensure that the injector cable passage (à) is
seated correctly.
Tightening torque
Cylinder head cover....................................22 Nm
WA 74 (3rd)1.10 - 3
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITHOUT EVB
Removing the engine barring gear
1
• Unscrew the engine barring gear
• Screw the cover
1
onto the flywheel housing and
tighten it
• Lower the cab
Pressure flange nuts for injector nozzle holders
Retightening (omitted in the case of D2876 LF 12/13)
During the first service (E service), retighten the
pressure flange nuts for the injector nozzles (à) by
90°, referring to SI 95500 "Injector nozzle".
After retightening the pressure flange nuts, affix a
yellow-coloured dot next to the adhesive label for
cylinder head bolt retightening. Affix this coloured dot
following all first services performed up until the end
of 2003.
There is no need to affix the coloured dot
after this date.
1.10 - 4WA 74 (3rd)
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITHOUT EVB
CHECKING THE VALVE CLEARANCE (alternative method)
1
2
123456
123456
Alternative method for adjusting valve clearance in D2866 And D2876 engines
This alternative method enables all valves to be checked and adjusted in just two crankshaft positions.
The method described here can be used as an alternative to the usual method already described.
Adjustment
• Fit the engine barring gear on the flywheel housing
(à) (see page 1)
• Turn the crankshaft until it reaches the nearest
TDC position so that either cylinder 1 or cylinder 6
is at ignition TDC
• 6 valves can be adjusted in this position
• Then turn the engine 1 more revolution so it
reaches TDC again
• The remaining 6 valves can now be adjusted
Cylinder 1 or cylinder 6 must be exactly
at the TDC mark.
If cylinder 6 is at ignition TDC (= cylinder 1 in
overlap), adjust:
ò Exhaust valves and ò intake valves
•
Intake valves
Exhaust valves
If cylinder 1 is at ignition TDC (= cylinder 6 in
overlap), adjust:
ò Exhaust valves and ò intake valves
•
1
2
Intake valves
Exhaust valves
• Remove the engine barring gear
Fit the cover on the flywheel housing.
WA 74 (3rd)1.10 - 5
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITH EVB
FOUR-VALVE – WITH EVB
1
2
3
1
2
D2866 LF 26/27/28/32/36/37 and
D2876 LF 04/05/07/12/13
Engines with 4-valve cylinder heads and EVB
(Exhaust Valve Brake) are indicated by the plate
opposite on one of the valve covers.
Valve clearance for checking/adjustment:
E = intake valve bridge/rocker arm
D2866 LF; D2876 LF.........................0.50 mm
A1= exhaust valve bridge/rocker arm
D2866 LF; D2876 LF.........................0.60 mm
A2= exhaust valve bridge/counter-holder
D2866 LF; D2876 LF.........................0.40 mm
VALVE CLEARANCE
Checking (engine no more than lukewarm)
• Stop the engine
• Tilt the cab
Fitting the engine barring gear
• Remove the cover from the flywheel housing
• Fit the engine barring gear, MAN no.
80.99626-6008
This engine barring gear allows the flywheel to be
1
blocked with pin
2
or 3.
in the desired position using hole
• Attach the gear ratchet, MAN no. 80.99627-0001
Removing the cylinder head cover
• Unscrew and remove the mounting bolts
• Remove the cylinder head cover and the cylinder
head gasket
Note (D2866 LF 26/27/28/32/36/37
D2876 LF 04/05/07):
1
Handle the gasket
connecting cable
sensor
(NBF) with care.
at the passage for the
2
for the needle movement
WA 74 (3rd)1.11 - 1
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITH EVB
Note (D2876 LF 12/13):
Rocker arm in overlap on
cylinder:
15362
4
Rocker arm relieved, check/
adjust valve clearance on
cylinder:
62415
3
123456
2
1
Handle the injector cable passage (à) with
care.
Cylinder order and valve arrangement
− Cylinder order: 1 to 6
− The 1st cylinder is at the fan end
− Firing sequence: 1 – 5 – 3 – 6 – 2 – 4
1 Fan end
2 Gearbox end (power output)
Intake valves
Exhaust valves
• Move the piston of the cylinder requiring
adjustment to ignition TDC. To do this:
Use the engine barring gear to turn the flywheel
until the rocker arms on the cylinder concerned
have been relieved; the flywheel can be blocked in
this position.
The rocker arms of the synchronous cylinder are
then in overlap.
The valve bridge must be pushed down
as far as the stop during all checks.
Make sure that the valve bridge and the
contact surface of the adjuster screws
are not tilted, otherwise the feeler gauge
will jam and a false reading will be
obtained.
1.11 - 2WA 74 (3rd)
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITH EVB
Intake valves
2
1
2
1
4
1
2
3
Desired valve clearance:
Intake valve bridge/rocker arm
D2866 LF; D2876 LF ..............................0.50 mm
• Use the feeler gauge to measure the clearance
between the rocker arm
1
and the bridge
2
You must be able to move the feeler gauge with little
resistance.
Adjust the valve clearance if the desired value is not
obtained.
Exhaust valves (with EVB)
• Pull the foot on the adjusting screw upwards so
that the remaining oil can escape
Desired valve clearance:
Exhaust valve bridge/rocker arm
D2866 LF; D2876 LF ..............................0.60 mm
• Use the feeler gauge to measure the clearance
between the rocker arm
1
and the bridge
2
You must be able to move the feeler gauge with little
resistance.
Adjust the valve clearance if the desired value is not
obtained.
Desired valve clearance (EVB):
Exhaust valve bridge/counter-holder
D2866 LF; D2876 LF ..............................0.40 mm
• Use the feeler gauge to measure the clearance
between the counter-holder
3
and the bridge
2
You must be able to move the feeler gauge with little
resistance.
Adjust the valve clearance if the desired value is not
obtained.
Adjusting (with the engine cold)
The piston of the cylinder which requires adjustment
must be at ignition TDC.
Note: Use valve setting key to adjust the valves.
1 Torque wrench
MAN no. 08.06450-0006
2 Valve setting key WAF 14
MAN no. 08.06455-0029
3 Valve setting key WAF 21
MAN no. 08.06455-0030
4 Hexagon socket screw wrench
MAN no. 08.06125-9035
WA 74 (3rd)1.11 - 3
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITH EVB
Intake valves
2
1
123
• Undo lock nut
2
on the rocker arm using
the valve setting key
Desired valve clearance:
Intake valve bridge/rocker arm
D2866 LF; D2876 LF..............................0.50 mm
1
• Use valve setting key to turn adjuster screw
until
the feeler gauge can be moved between the rocker
arm and the bridge with little resistance
D2866 LF; D2876 LF..............................0.60 mm
Exhaust valve bridge/counter-holder
D2866 LF; D2876 LF..............................0.40 mm
• Use the valve setting key to undo the lock nut
1
and unscrew the adjuster screw 2 in the counterholder until the contact surface of the adjuster
screw disappears in the counter-holder
3
• Use the valve setting key to undo lock nut 1 and
2
unscrew adjuster screw
until the feeler gauge
can be inserted between the valve bridge and the
adjuster screw
• Screw in the adjuster screw
2
until the piston
3
reaches the stop and the feeler gauge clamps (so
that the remaining oil is forced out of the ball
socket)
2
• Turn back adjuster screw
but only far enough to
enable the feeler gauge to be moved between the
rocker arm and the bridge with little resistance
• Tighten lock nut
1
Tightening torque
Lock nut for valve adjuster screw ................. 45 Nm
2
• Screw in adjuster screw
so that the feeler gauge
can still be inserted between the counter-holder
and the bridge
• Insert the feeler gauge and screw in adjuster screw
2
until the piston reaches the stop and the feeler
gauge clamps
2
• Turn back adjuster screw
but only far enough to
enable the feeler gauge to be pulled out with little
resistance
• Tighten lock nut
1
Tightening torque
Lock nut and valve adjuster screw................ 45 Nm
Double check: There must be play on the push rod!
1.11 - 4WA 74 (3rd)
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITH EVB
Fitting the cylinder head cover
1
2
1
Note: Non-damaged valve cover and intake seals
made from aluminium/elastomers can be
reused.
• Fit the cylinder head cover gasket (elastomer) onto
the cylinder head cover
• Fit the cylinder head cover
Note (D2866 LF 26/27/28/32/36/37
D2876 LF 04/05/07):
1
Ensure that the gasket
the connecting cable
movement sensor
at the passage for
2
for the needle
(NBF) is seated correctly.
Note (D2876 LF 12/13):
Ensure that the injector cable passage (à) is
seated correctly.
Tightening torque
Cylinder head cover....................................22 Nm
Removing the engine barring gear
• Unscrew the engine barring gear
1
• Screw cover
onto the flywheel housing and
tighten it
• Lower the cab
Pressure flange nuts for injector nozzle holders
Retightening (omitted in case of D2876 LF 12/13)
Retighten the pressure flange nuts (à) by 90° during
the first service, referring to SI 95500 "Injector
nozzle".
After retightening the pressure flange nuts, affix a
yellow-coloured dot next to the adhesive label for
cylinder head bolt retightening. Affix this coloured dot
following all first services performed up until the end
of 2003.
There is no need to affix the coloured dot
after this date.
WA 74 (3rd)1.11 - 5
ENGINE D 2866 LF, D 2876 LF, FOUR-VALVE – WITH EVB
CHECKING THE VALVE CLEARANCE (alternative method)
1
2
123456
123456
Alternative method for adjusting valve clearance in D2866 and D2876 engines
This alternative method enables all valves to be checked and adjusted in just two crankshaft positions.
The method described here can be used as an alternative to the usual method already described.
Adjustment
• Fit the engine barring gear on the flywheel housing
(à) (see page 1)
• Turn the crankshaft until it reaches the nearest
TDC position so that either cylinder 1 or cylinder 6
is at ignition TDC
• 6 valves can be adjusted in this position
• Then turn the engine 1 more revolution so it
reaches TDC again
• The remaining 6 valves can now be adjusted
Cylinder 1 or cylinder 6 must be exactly
at the TDC mark.
If cylinder 6 is at ignition TDC (= cylinder 1 in
overlap), adjust:
ò Exhaust valves and ò intake valves
•
Intake valves
Exhaust valves
If cylinder 1 is at ignition TDC (= cylinder 6 in
overlap), adjust:
Exhaust valves and ò intake valves
ò
•
1
2
Intake valves
Exhaust valves
• Remove the engine barring gear
Fit the cover on the flywheel housing.
1.11 - 6WA 74 (3rd)
ENGINE D 0836 LF, FOUR-VALVE – WITH EVB
FOUR-VALVE – WITH EVB (D0836 LF 41, 44)
1
2
3
1
4
EVB = Exhaust Valve Brake
CHECKING THE VALVE CLEARANCE (engine no
more than lukewarm)
• Stop the engine
• Tilt the cab
1
• Remove the cover
from the flywheel housing
Fitting the engine barring gear
• Fit the engine barring gear, MAN no.
80.99626-6008
This engine barring gear allows the flywheel to be
1
blocked with pin
2
or 3.
in the desired position using hole
• Attach the gear ratchet, MAN no. 80.99627-0001
Removing the cylinder head cover
• Remove the plug for the injector
• Turn (à) and remove the lock
4
• Unscrew and remove the mounting bolts (à) from
the cylinder head cover
• Remove the cylinder head cover with gasket
WA 74 (3rd)1.12 - 1
ENGINE D 0836 LF, FOUR-VALVE – WITH EVB
Cylinder order and valve arrangement
I
I
II
I
123456
2
1
2
1
2
1
− Cylinder order: 1 to 6
− The 1st cylinder is at the fan end
− Firing sequence: 1 – 5 – 3 – 6 – 2 – 4
1 Fan end
2 Gearbox end (power output)
Intake valves
Exhaust valves
• Move the piston of the cylinder requiring
adjustment to ignition TDC. To do this:
Use the engine barring gear to turn the flywheel
until the valves on the cylinder concerned have
been relieved; the flywheel can be blocked in this
position.
The rocker arms of the synchronous cylinder are
then in overlap.
Valves in overlap, cylinder:
624153
I
Check/set valve clearance, cylinder:
Valve clearance (with the engine cold)
Intake valve.............................................0.50 mm
Exhaust valve..........................................0.50 mm
Counter-holder EVB................................0.35 mm
Intake valve
Desired valve clearance:
Intake valve.............................................0.50 mm
• Insert the feeler gauge (ä) between rocker arm
2
and valve bridge 1.
You must be able to move the feeler gauge with little
resistance.
Adjust the valve clearance if the desired value is not
obtained.
Exhaust valve with EVB
Desired valve clearance:
Exhaust valve/rocker arm.......................0.50 mm
Counter-holder EVB ...............................0.35 mm
153624
• Use the feeler gauge to measure the clearance
2
between the rocker arm
and the valve bridge
• Use the feeler gauge to measure the clearance
1
between the counter-holder
and the valve bridge
You must be able to move the feeler gauge with little
resistance.
Adjust the valve clearance if the desired value is not
obtained.
1.12 - 2WA 74 (3rd)
ENGINE D 0836 LF, FOUR-VALVE – WITH EVB
ADJUSTING THE VALVE CLEARANCE (with the
2
1
1
3
2
4
2
1
3
engine cold)
The piston of the cylinder which requires adjustment
must be at ignition TDC.
Note: The new valve setting key can be used to
adjust the valves.
1 Torque wrench
MAN no. 08.06450-0006
2 Insert ring
MAN no. 08.06455-0029
3 Hexagon socket screw wrench
MAN no. 08.06125-9035
Intake valves
• Insert the feeler gauge (ä) between rocker arm
and valve bridge
1
2
• Undo lock nut 3 on the rocker arm using the valve
setting key
• Use the valve setting key to turn the adjuster screw
4
until the feeler gauge can be moved with little
resistance
Desired valve clearance:
Intake valve .............................................0.50 mm
• Tighten the lock nut
• Re-check the valve clearance and adjust if
necessary
Tightening torque
Lock nut for valve adjuster screw..................45 Nm
Exhaust valve with EVB
1
• Insert the feeler gauge between rocker arm
and
the valve bridge
• Undo the lock nut on the rocker arm using the
valve setting key
• Use the valve setting key to turn the adjuster screw
until the feeler gauge can be moved with little
resistance
Desired valve clearance:
Exhaust valve/rocker arm .......................0.50 mm
• Tighten the lock nut
• Re-check the valve clearance and adjust if
necessary
• Insert the feeler gauge between counter-holder
2
and the valve bridge
• Undo the lock nut on the rocker arm using the
valve setting key
• Use the valve setting key to turn the adjuster screw
until the feeler gauge can be moved with little
resistance
Desired valve clearance:
Counter-holder EVB................................0.35 mm
• Tighten the lock nut
• Re-check the valve clearance and adjust if
necessary
Tightening torque
Lock nut for valve adjuster screw..................45 Nm
Double check: There must be play on the push rod!
WA 74 (3rd)1.12 - 3
ENGINE D 0836 LF, FOUR-VALVE – WITH EVB
Fitting the cylinder head cover
1
1
2
When fitting the cylinder head cover with gasket,
1
ensure that the injector plug lug
2
lock
for the cylinder head cover (inside).
is seated in the
• Fitting of the cylinder head cover is a reversal of
the removal procedure
Tightening torque
Mounting bolts for cylinder head cover......... 12 Nm
Removing the engine barring gear
• Unscrew the engine barring gear
1
• Screw cover
onto the flywheel housing and
tighten it
• Lower the cab
1.12 - 4WA 74 (3rd)
ENGINE D 0836 LF, FOUR-VALVE – WITH EVB
CHECKING THE VALVE CLEARANCE (alternative method)
1
2
123456
123456
1
2
Alternative method for adjusting valve clearance in D 0836 engines
This alternative method enables all valves to be checked and adjusted in just two crankshaft positions.
The method described here can be used as an alternative to the usual method already described.
Adjustment
• Fit the engine barring gear on the flywheel housing
(à) (see page 1)
• Turn the crankshaft until it reaches the nearest
TDC position so that either cylinder 1 or cylinder 6
is at ignition TDC
• 6 valves can be adjusted in this position
• Then turn the engine 1 more revolution so it
reaches TDC again
• The remaining 6 valves can now be adjusted
Cylinder 1 or cylinder 6 must be exactly
at the TDC mark.
If cylinder 6 is at ignition TDC (= cylinder 1 in
overlap), adjust:
Exhaust valves and ò intake valves
ò
•
Intake valves
Exhaust valves
If cylinder 1 is at ignition TDC (= cylinder 6 in
overlap), adjust:
ò Exhaust valves and ò intake valves
•
Intake valves
Exhaust valves
• Remove the engine barring gear
Fit the cover on the flywheel housing.
WA 74 (3rd)1.12 - 5
ENGINE D2866 LF, D2876 LF, D0836 LF
CHANGING ENGINE OIL AND FITTING A NEW
1
FILTER
• Park the vehicle on a flat, level surface
• Switch off the ignition
Draining the oil (with engine at operating
temperature)
Note: A new oil filter is also fitted each time the
engine oil is changed.
When the oil is changed, you may notice that a
quantity of used oil (0.3 litres when ECAS is at
normal level and vehicle is parked on the flat)
remains in the oil sump overflow area. This is due to
the shape of the oil sump. The actual quantity
depends on how far the vehicle is lowered at the
rear.
If ECAS is fitted, you should raise the rear of the
vehicle as far as possible when changing the oil so
that all of the used oil can flow out.
Note: The vehicle must be standing on a flat,
level surface when the oil level is measured!
If necessary, switch ECAS (electronically
controlled air suspension) to the normal level,
see sections 3.00 and 3.10/3.11 "ECAS" in the
Operator's Manual
The engine oil level falls when the rear axle is
lowered and rises when the rear axle is raised.
• Tilt the cab
• Put an oil pan or similar underneath
1
• Unscrew the oil drain plug
at the oil sump
(example illustrated)
You must comply with the notes on
safety regarding the treatment of used oil
and the disposal of oil filter elements,
see section 0.50 "NOTES ON SAFETY
AND ENVIRONMENTAL PROTECTION"!
Drain the used oil from the oil sump drain hole
WA 74 (3rd)1.20 - 1
ENGINE D2866 LF, D2876 LF, D0836 LF
Fitting a new oil filter element
3
2
4
531
4
5
3
− − The oil filter cover is made of plastic.
− − Do not exceed the specified torque.
− − Only use genuine MAN parts.
2
• Undo the oil filter cover using special tool
no. 80.99606–0508) until sealing ring
(MAN
3
becomes
visible
• • Do not pull out the oil filter cover and oil filter
element until the used oil has drained out of the
oil filter bowl
• Pull the filter element off the cover
• Renew sealing rings
3, 4
and
5
Danger of engine damage!
You must make sure sealing ring
3
is
seated correctly!
• Insert the new filter element
• Insert and tighten oil filter cover and filter element
Fire risk!
Always clean the noise shield before
refitting it if it is removed to carry out any
work.
Do not leave any cleaning wool, cloths
etc. lying in the noise shield!
1.20 - 2WA 74 (3rd)
ENGINE D2866 LF, D2876 LF, D0836 LF
Danger of engine damage!
I
I
6
I
7
OIL LEVEL
M
8
II
Oil level
7
− − Only used MAN-approved engine oils,
see "MAINTENANCE
RECOMMENDATIONS AND
RECOMMENDED SERVICE
PRODUCTS" booklet.
Do not overfill!
− Never fill the oil past the MAX mark (àà)
on dipstick
on the "OIL LEVEL" gauge
driver's display (Baseline figure
Highline figure
This merely causes oil to be pumped
through the engine vents and is
uneconomical.
6
or on the MAX indicator
7
on the
I
).
or
INMAX
• Lower the cab
• Open the front flap
• Pour in the engine oil through filler neck
The oil levels indicated on the driver's display and
the dipstick may be different. You should therefore
proceed as described on the following pages.
25.10.2002) and the instructions for measuring the
oil level on page 1.20 - 1!
The oil level is measured every 10 seconds when the
ignition is switched on. This measured value is
stored and can be called up on the driver's display.
If the engine is started and stopped, there is then a
delay to allow the engine oil to flow back into the oil
sump. The length of this delay depends on the
engine oil temperature, see "Delay" table on page
1.20 - 5.
The vehicle must be standing on a flat, level
surface when the oil level is measured!
• Switch on the ignition
• Call up the engine oil level using the menu on the
driver's display (see Operator's Manual for "Menu
structure". Check the oil level and correct as
necessary
• Start the engine and run it at idling speed until oil
9
pressure check lamp
lamps goes out (Baseline figure
I
figure
)
on the panel of check
and Highline
Danger of engine damage!
Never run the engine at high revs or
under load until the minimum oil
pressure has been reached.
• Stop the engine
• Switch off the ignition
Note: After the engine has been running, there will
be up to 2 to 5 litres of engine oil in the engine
block, depending on viscosity, engine oil
temperature and time. This oil flows back into
the oil sump after the engine is stopped.
The time the oil takes to flow back into the
sump depends heavily on the viscosity and the
temperature. The correct oil level can only be
measured once all the oil in the engine has
flowed back into the oil sump.
The "Delay" table (page 1.20 - 5) indicates the
delay required before the correct oil level can
be ascertained. This delay depends on the
engine oil temperature at the time the engine
is stopped.
1.20 - 4WA 74 (3rd)
ENGINE D2866 LF, D2876 LF, D0836 LF
The following delays apply when measuring the oil
Oil temperature (in °C)
Delay (in minutes)
-40
180
0
90
+20
45
+50
5
+80
4
+110
3
0
I
I
10
OIL TEMPERATURE
10
Oil temperature
6
I
II
level after stopping the engine:
..................................
....................................
....................................
......................................
......................................
......................................
100.0 °C
• Call up the oil temperature
display menu (Baseline figure
I
figure
; special equipment; see Operator's
1
using the driver's
and Highline
Manual for "Menu structure")
• Tilt the cab
• Use the "Delay" table (see above) to ascertain the
required delay. You must wait this length of time so
that all the oil can collect in the sump. You can
then measure the correct engine oil level
6
• Pull out dipstick
, check the engine oil level and
correct it as necessary
The oil level must be between the top and bottom
marks (notches, à) on the dipstick.
Top-up quantity
Between MIN and MAX marks on the dipstick, see
"MAINTENANCE RECOMMENDATIONS AND
RECOMMENDED SERVICE PRODUCTS" booklet.
• Check the engine and the oil filter housing for leaks
• Lower the cab
• After 15 minutes, call up the engine oil level on the
driver's display menu, check the level and correct it
again as necessary
Do not overfill!
100.0 °C
Note: The oil levels indicated on the driver's display
and the dipstick should be about the same,
although slight differences (approx. 2 litres)
are possible.
The levels indicated on the dipstick and the
driver's display may differ by about ± 5 mm.
− − Differences in levels measured with the
engine hot and cold are normal.
− − The only totally reliable method of
establishing the oil level is with the engine
cold after the vehicle has been parked on
a flat, level surface for several hours.
− Never top up with oil so the level exceeds
the MAX mark on the driver's display or on
the dipstick.
This merely causes oil to be pumped
through the engine vents and is
uneconomical.
WA 74 (3rd)1.20 - 5
ENGINE D2866 LF, D2876 LF, D0836 LF
TOPPING UP THE ENGINE OIL
I
I
8
I
7
OIL LEVEL
M
II
Oil level
7
• Switch off the ignition
• Open the front flap
Danger of engine damage!
− − Only used MAN-approved engine oils,
see "TECHNICAL DATA" section
and/or "MAINTENANCE
RECOMMENDATIONS AND
RECOMMENDED SERVICE
PRODUCTS" booklet.
Do not overfill!
− − There is absolutely no need to top up
to the MAX mark continuously.
− Never fill the oil past the MAX
indicator (ââ) on the driver's display
(Baseline figure
I
).
This merely causes oil to be pumped
through the engine vents and is
uneconomical.
• Top up the oil to the correct level through filler neck
8
• Call up the engine oil level
the driver's display, check the oil level and correct
as necessary (see Operator's Manual for "Menu
structure")
or Highline figure
7
using the menu on
INMAX
Note: The new oil level will only be indicated
correctly if you wait the specified time between
turning off the ignition and turning it back on
again, see "Delay" table on page 1.20 - 5.
Top-up quantity
Between MIN and MAX marks, see "MAINTENANCE
RECOMMENDATIONS AND RECOMMENDED
SERVICE PRODUCTS" booklet.
MINMAX
1.20 - 6WA 74 (3rd)
INTAKE SYSTEM
DRY AIR FILTER
I
I
Change
air filter
I
Change
air filter
II
1
2
FILTER ELEMENT
A dirty air filter is indicated on the driver's display by
the "Change air filter" message (Baseline figure
and Highline figure
I
).
Note: Change the filter at least every 2 years or
200,000 km, whichever comes first, or when
the driver's display indicates the time interval
or the mileage.
Danger of engine damage!
− − Do not fit a new filter element unless
the engine is stopped.
− − Unnecessary filter servicing reduces
the effectiveness of the filter.
− Ensure cleanliness when changing the
filter.
− − There must be no dirt on the clean air
side!
Removing the filter element
• Stop the engine
• Tilt the cab
1
• Unfasten all 4 clips
• Remove filter cover
on the air filter housing
2
• • Grasp the filter element by the surrounding
protective cover only and pull it out of the housing
WA 74 (3rd)1.60 - 1
INTAKE SYSTEM
Checking the water drain valve
3
3
3
Water drain valve
is located upstream of the air
filter at the lowest point of the crude air pipe.
Danger of engine damage!
Regularly clean and check the
functioning of water drain valve
there may be water in the crude air pipe
when the drain valve is closed.
This causes water to be sucked in,
resulting in engine damage!
3
as
• • Use your hand to check the water drain valve
for free passage
• • Clean the valve if it is blocked
3
1.60 - 2WA 74 (3rd)
INTAKE SYSTEM
Installing the filter element
4
512
• Clean the air filter housing and cover
Danger of engine damage!
Never blow out the air filter housing with
compressed air!
Using genuine filter elements is the only way to
ensure that particles can not enter the clean air
system.
The filter element must be radially positioned against
4
the contact surface
of the clean air pipe so that it
forms an air-tight seal (radial seal).
Do not use standard cartridges which offer axial
sealing.
• Insert new filter element
5
into the centre of the
filter housing from the left-hand side of the vehicle
until the stop is reached
Make sure the filter element is not tilted and that the
seals on the end of the element are seated over the
clean air pipe.
• Check that the filter element is correctly positioned
in the housing
However, the filter element must be pushed right into
the end of the bowl, otherwise the housing filter
cover cannot be closed or, if it is forced closed, this
may push in the filter cartridge.
Note: Never force the air filter housing closed. If in
doubt, recheck the filter element to make sure
it is correctly seated.
• Fit the filter cover
2
and fasten the clips
1
one by
one, working diagonally across
Danger of engine damage!
− − Unfiltered air can get into the engine if
the filter cover or the filter element are
not fitted correctly.
− − Check that all fasteners on the intake
system are sealed. Retighten the
clamps if necessary.
− − Do not over-tighten the worm screws.
• Lower the cab
WA 74 (3rd)1.60 - 3
COOLING AND HEATING SYSTEM
COOLING AND HEATING SYSTEM
1
231
CONDITION, CORRECT FUNCTIONING AND
LEAK-TIGHTNESS
Testing
• Check the condition and leak-tightness of the
coolant lines
• Check the condition and leak-tightness of the
radiator, intercooler and air-conditioning condenser
Clean the insect screen, radiator fins and condenser
(special equipment, see section 8.90) if there is a
heavy build-up of dirt.
INSECT SCREEN AND RADIATOR FINS
Cleaning
• Stop the engine and open the front flap
• Remove the insect screen by first unclipping the
1
springs
screen
using pliers whilst holding the insect
2
steady
• Then unclip the insect screen at the left and right
3
bottom lug
(â)
• Pull the insect screen upwards to remove it and
then clean it
− − Do not direct the water jet at the
heating/ventilation intake opening!
− Close the fresh air flaps for the heating
system!
− Do not use high-pressure cleaners!
− − Steam cleaners may be used.
• Clean the dirty fins (ß) on the radiator, intercooler
and air-conditioning condenser using a solution of
water and P3–Begesol cleaning additive (MAN no.
09.21002-0248) mixed 1:1
• Use a spray gun to spray the cleaning fluid straight
at the fins and make the spray jet as concentrated
as possible
• Leave to act for about 5 minutes
• Flush out with a concentrated jet of tap water
Repeat the procedure if the fins are very dirty!
Note: Ensure that the insect screen is installed the
1
correct way round as the springs
cannot be
turned. The figure opposite shows the correct
1
attachment position (à) for the springs
.
• Reinstall the insect screen (reversal of the removal
procedure)
WA 74 (3rd)1.70 - 1
COOLING AND HEATING SYSTEM
TIGHTENING COOLING SYSTEM HOSE CLAMPS
1
3
2
44
Retighten the cooling system hose clamps during the
running-in service.
Tightening torques
1)
Entire cooling system 2):
Standard part M3259 (belt width 12 mm).... 5.0 Nm
Breather line on expansion tank:
Standard part M7.751-30 (belt width 9 mm).. 3.5 Nm
1)
also see Service Information 33900b dated
08.07.2002
2)
with the exception of breather line on expansion
tank
CHANGING THE COOLANT
The following must be changed every 500,000 km or
4 years as specified in the "Checklist for
maintenance work" section:
− Coolant
− Pressure-relief valve
1
, see page 6
Dispose of used coolant in the correct manner; refer
to section 0.50 "Environmental protection".
Danger of scalding!
− Only open filler neck screw cap
2
when the engine is cool or the cooling
system is depressurised; otherwise,
there is a risk of scalding!
− − Carefully open the pressure-relief valve
1
. Allow the excess pressure to
escape and then close it again.
• Set the vehicle heating to full power
• Stop the engine
• Tilt the cab
Draining the coolant
• Collect the coolant in suitable containers and
dispose of it in the correct manner
2
• Screw off the cap
• Unscrew the drain plugs
on the filler neck
3
and
4
• Open the temperature control lever, do not pull
hoses off the cab
and Recommended Service Products" booklet or
section 0.70, "Technical data"
• Make sure the coolant is of a sufficient
concentration, see page 4 and 5
• Slowly pour in the coolant through the filler neck
until it overflows
• Plug the filler neck
• Start the engine and let it run at idling speed for
about 5 minutes
• Check the cooling and heating system for leaks
• Stop the engine
• Check the coolant level shown on the tank viewing
window
2
When the engine is cold, the coolant level should be
slightly lower than the middle of the viewing window
(à).
• Correct the coolant level if necessary
• Re-check the coolant level after max. 5 hours
driving (see page 7) and top up the coolant if
necessary
2
WA 74 (3rd)1.70 - 3
COOLING AND HEATING SYSTEM
COOLANT MIXING RATIO
:
Outside air
temperature
Antifreeze
40% by volume
45% by volume
50% by volume
2
2
Vehicle with PriTarder:
In the case of the PriTarder, the coolant
composition deviates from the MAN
standard and is 50% tap water and 50%
BASF–Glysantin G48. The composition
does not depend on the application
temperature.
Failure to ensure the correct coolant
composition will almost certainly lead to
PriTarder damage.
Check the concentration of the coolant before the
onset of cold weather and increase it if necessary.
The coolant is a mixture of water and anti-freeze with
corrosion protection (to Works Standard MAN 324).
Note: In the case of individual applications for which
the use of antifreeze is not a specified
requirement (e.g. in the tropics), always
ensure that a corrosion protection agent is
used (as per Works Standard MAN 248). The
change interval for this coolant depends on
the type of corrosion protection agent used,
see page 5.
Checking the antifreeze (to MAN 324)
• Warm up the engine
• Stop the engine
• Open the front flap
Danger of scalding!
− Only open filler neck screw cap
2
when the engine is cool or the cooling
system is depressurised; otherwise,
there is a risk of scalding!
• Open the cap
2
on the filler neck
• Use a hydrometer to take a sample of coolant and
read off the coolant density indicated by the float
The antifreeze must offer protection down to at least
-25 °C.
Mixtures of antifreeze MAN 324 and
corrosion protection agent MAN 248 are
not permitted.
If the antifreeze check reveals less effective
protection than this, e.g. only down to -10 °C, drain
some coolant and top up the system with undiluted
antifreeze as indicated in the mixing table.
• Close the cap on the filler neck
• Perform a test run
Make sure the engine reaches its operating
temperature, i.e. the thermostat must have opened
fully on at least one occasion.
• Use a hydrometer to recheck the coolant density
and correct if necessary
Mixing table
down to ...
-27 °C............
-31 °C............
-37 °C............
Water
.. 60% by volume
.. 55% by volume
.. 50% by volume
1.70 - 4WA 74 (3rd)
COOLING AND HEATING SYSTEM
Checking the corrosion protection agent
(to MAN 248)
In the case of individual applications for which the
use of antifreeze is not a specified requirement (e.g.
in the tropics, stationary engines), always ensure
that a corrosion protection to MAN 248 is used.
Mixtures of antifreeze MAN 324 and
corrosion protection agent MAN 248 are
not permitted.
Drain all the coolant when changing from antifreeze
to corrosion protection agent or vice versa. It is not
necessary to flush the system.
The following corrosion protection agents are
currently approved by MAN:
− Fleetguard DCA II Fluid
− Texaco Havoline XLI (ETX 6282)
In the case of Fleetguard DCA II Fluid, the following
applies:
− Change all the coolant after 1 year or 1500
operating hours, whichever comes first.
− Check the concentration of Fleetguard DCA II
Fluid using Fleetguard–Test–Kit 3300–846 S every
300 operating hours.
− Ensure the concentration is between 0.8 and
1.5 DCA II units per 4 litres of water, equivalent to
240 to 450 ml of fluid to 10 litres of water (2.4 to
4.5% by volume).
In the case of Texaco Havoline XLI (ETX 6282), the
following applies:
− Change all the coolant after 2 years or 3000
operating hours, whichever comes first.
− Check that the concentration is 10% by volume
using a refractometer.
WA 74 (3rd)1.70 - 5
COOLING AND HEATING SYSTEM
PRESSURE-RELIEF VALVE ON THE EXPANSION
1
2
1
TANK
Renewing
The following must be changed every 500,000 km or
4 years as specified in the "Checklist for
maintenance work" section:
− Pressure-relief valve
1
− Coolant, see page 2
Danger of scalding!
Carefully open pressure-relief valve
1
and release the excess pressure.
• Stop the engine
• Tilt the cab
• Fit a new pressure-relief valve
1
• Lower the cab
AIR INLET FOR HEATING / VENTILATION /
AIR-CONDITIONING SYSTEM:
DUST FILTER
Renewing
• Stop the engine
• Open the front flap
• Unfasten the retaining clips at the bottom of the
1
cover
(á)
• Lift and remove the cover
• Take out the filter
• Fit the cover
• Close the front flap
2
and insert a new filter
1.70 - 6WA 74 (3rd)
COOLING AND HEATING SYSTEM
COOLANT LEVEL
2
1
1
Checking
• Stop the engine
• Open the front flap
• Check the coolant level shown on the
tank viewing window
2
When the engine is cold, the coolant level should be
slightly lower than the middle of the viewing window
(à).
• If necessary, slowly top up the coolant through filler
1
neck
TOPPING UP THE COOLANT
Danger of scalding!
Only open the filler neck screw cap
1
once the engine has cooled down.
Otherwise, there is a risk of scalding!
Carefully open the screw cap. Allow the
excess pressure to escape before
screwing off the cap.
• Carefully open the screw cap
1
• If the engine is at operating temperature, slowly top
up to desired level with warm coolant if possible
• Make sure the coolant is of a sufficient
concentration, see page 4 and 5
• Screw on the cap
• Close the front flap
WA 74 (3rd)1.70 - 7
POLY-V-BELTS
POLY-V-BELTS D2876/66 LF
1
1
1
1
11
4
3
11
1
6
7
8
2
346
782
5
(example illustrated, with ducted fan removed)
CONDITION
Checking
1
• Check the poly-V-belts
for cracks, oily patches,
vitrification and wear
Renew poly-V-belts that are damaged or worn.
7
• Visually inspect the spring damper element
for
oil leaks when untensioned
Have any leaks repaired immediately by a MAN
Service workshop.
TENSION
Checking
• Stop the engine
• Tilt the cab
1
• Place setting gauge
over the bolt heads
damper element
If it is possible to place the setting gauge
6
bolt heads
and
(MAN no. 80.99607-6014)
6
7
8
without using force, this
and
8
of the spring
1
over the
indicates that the automatic V-belt tensioner has the
correct pretension.
• Tension poly-V-belts if necessary
Tensioning (basic setting)
The automatic V-belt tensioner consists of a spring
7
damper element
• Firmly hold the counter-holder
and requires a basic setting.
4
using a ring
spanner (size 19) and note the rotation direction of
5
the eccentric plate
(risk of crushing)!
It is vital that slackening and tensioning
of the spring damper be performed
slowly in order to prevent accidents (risk
of crushing) and damage to the spring
damper element
• Undo size-13 collar bolts
5
eccentric plate
counter-holder
, making absolutely sure that the
4
is held firmly
• Undo mounting bolts
damper element
7
the counter-holder
7
.
2
and 3 on the
8
and 6 on the spring
, making absolutely sure that
4
is held firmly and released
slowly
• Use the size-19 ring spanner to increase the
7
pretension of the spring damper element
4
counter-holder
setting gauge
until it is possible to place the
1
onto the bolt heads 6 and
on the
8
• Then tighten mounting bolts 2 and 3 by hand
• Remove the setting gauge
1
It must be possible to pull off the setting gauge
without using force. Retension poly-V-belts if
necessary
WA 74 (3rd)1.80 - 1
POLY-V-BELTS
• Tighten mounting bolts 6 and 8 on the spring
0
0
2
3
4
13
12
3
46782
536
8
2
10
9
14
1
7
damper element
• Tighten collar bolts 2 and
7
3
• Check the tightening torque of mounting bolts
1
and
Tightening torques
Collar bolts (size 13)
2
Spring damper element (size 17)
Spring damper element (size 13)
Mounting bolt (size 22)
Mounting bolt (size 10)
3
and
9
1
..................... 35 Nm
6
............. 43 Nm
8
............. 22 Nm
........................... 150 Nm
............................. 50 Nm
RENEWING
1
• Undo the mounting bolt
• Undo the mounting bolts
• Firmly hold the counter-holder
for the cable clamp
1
for the fan clutch
4
using a ring
spanner (size 19) and note the rotation direction of
5
the eccentric plate
(risk of crushing)!
It is vital that slackening and tensioning
of the spring damper be performed
slowly in order to prevent accidents (risk
of crushing) and damage to the spring
damper element
7
.
9
• Undo mounting bolts
that the counter-holder
2
, 3, 8 and 6, making sure
4
is held firmly and
released slowly
1
• Press the fan clutch
• Feed the poly-V-belt
towards the radiator
1
through the gap at the fan
flange and remove it
7
• Check the spring damper element
for oil leaks
Have any leaks repaired immediately by a MAN
Service workshop.
vitrification and wear
Renew poly-V-belts that are damaged or worn.
Have any leaks repaired immediately by a MAN
Service workshop.
Example illustrated for D0836 LF engine with airconditioning system
RENEWING
• Remove the casing fan
1
WA 74 (3rd)1.80 - 3
POLY-V-BELTS
• Push the tensioning pulley 2 downwards
2
1
2
• Remove the poly-V-belt
1
Example illustrated for D0836 LF engine with airconditioning system
• Poly-V-belt installation is a reversal of the removal
procedure.
1.80 - 4WA 74 (3rd)
FUEL SYSTEM
FUEL SYSTEM
1
234
4
Always ensure complete cleanliness when
performing work on the fuel system!
Checking
• Visually inspect the condition of the fuel system
(damage and corrosion)
• Renew any defective parts
• Visually check the fuel system lines and ports for
leaks, particularly near components which reach
high temperatures during operation, e.g. injection
pump, injection nozzle, flame start system,
auxiliary heater, exhaust
• Immediately repair any leaks found
FUEL SERVICE CENTRE:
PRE-CLEANER STRAINER FILTER
Cleaning
• Stop the engine
• Tilt the cab
1
• Screw off the housing cover
using a ring
spanner, socket or special tool
• Remove and clean the cover and strainer insert
• Fit a new sealing ring
2
• Screw in and tighten the strainer insert and cover
(D2876LF12/13)
Also see Service Information 121700 "Fuel system"
dated 11.03.2003.
Important information!
− People with pacemakers must stay at
least 20 cm away from the running
engine.
− All work on components of the commonrail system must be performed by
specially trained personnel only.
− Before starting work, the engine must
remain stationary for at least 1 minute to
enable depressurisation of the rail
(pressure pipe). Check depressurisation
of the rail using MAN-Cats if necessary.
− Ensure absolute cleanliness in all work
and at all times (e.g. wash your hands,
wear clean work clothes). Avoid moisture
and humidity at all times.
− Always renew high-pressure lines and
pressure pipe connections once they
have been undone.
− Only use the "protective covering set"
special tool (MAN no. 81.96002–6005)
once!
− A jet of fuel can cut through the skin!
− Risk of fire due to fuel atomisation!
− Avoid standing near the running engine.
− Never undo the screwed connections on
the fuel high-pressure side whilst the
engine is running (injection line from the
high-pressure pump to/on the rail and on
the cylinder head to the injector).
− Do not touch the live parts at the injector
electrical connection whilst the engine is
running.
2
• Pull off the return line
pump
1
on the high-pressure
• Plug the return line using stopper, use protective
covering set (MAN no. 81.96002–6005)
• Unscrew the hand pump plunger
3
• Operate the hand pump until fuel emerges at the
high-pressure pump connection (ã) for the return
line
• Remove the stopper from the line
• Re-connect the return line
• Check that the common-rail fuel system is leak-
tight
1.90 - 2WA 74 (3rd)
FUEL SYSTEM
MAIN FILTER ELEMENT
7
6
5
8
Renewing
• Stop the engine
• Tilt the cab
• Screw off the housing cover
5
using a ring
spanner, socket or special tool
• Pull out the cover and filter element, but only once
the fuel in the filter bowl has flowed back into the
fuel tank
6
• Pull filter element
• Pull off sealing ring
off the cover
7
• Pull out the dirt bowl 8 and dispose of condensed
water and impurities in the correct manner
• Clean and reinsert the dirt bowl
8
• Clean the cover if necessary
• Fit a new sealing ring
• Fit a new filter element, noting the different filter
elements for CR engines and NON-CR engines
(CR = Common Rail)
• Screw in and tighten the filter element and cover
• Bleed the fuel system if necessary (see Operator's
Manual)
1.90 - 4WA 74 (3rd)
FUEL SYSTEM
AUXILIARY HEATER
5
6
Renewing the fuel supply filter
The fuel filter for the auxiliary heater is located in the
chassis frame between the cab and the fuel tank.
• Stop the engine
• Put a collecting container underneath
• Undo the hose clamps
• Fit a new filter
5
6
• Tighten the hose clamps
• If necessary, switch on the auxiliary heater several
times until it starts working correctly
WA 74 (3rd)1.90 - 5
CLUTCH
CLUTCH
1
2
FLUID LEVEL
Checking
• Park the vehicle on a flat, level surface
• Stop the engine
• Open the front flap
• Check the fluid level (à) in the expansion tank
1
Make sure the fluid level (à) in the expansion tank is
visible between the top MAX and bottom MIN marks.
If there is not enough fluid, find out why and rectify
the problem.
• Top up the fluid to the correct level through filler
Do not operate the Intarder immediately before
stopping the vehicle to check the oil level. This
ensures that the correct quantity of oil is set in the
gearbox.
Do not check the oil level immediately after driving
(incorrect reading). Only check once the gearbox has
cooled down.
Note: Each time you check the oil, also check the
gearbox, Intarder, oil/water heat exchanger
and their coolant pipes for possible leaks.
• Park the vehicle on a flat, level surface
• Stop the engine
• Put an oil pan or similar underneath
• Unscrew and remove oil filler plug
1
The oil must reach the bottom edge of the checking
and filler hole. Top up until oil overflows, if
necessary.
Do not operate the Intarder immediately before
stopping the vehicle to change the oil! This ensures
that the correct oil drain quantity is set in the
gearbox.
Note: Each time you change the oil, renew the oil
filter (see below) and, in the case of vehicles
with semilifetime oil fill, renew the breather,
see section 2.49.
Draining the oil
• Put an oil pan or similar underneath
3
• Unscrew oil drain plugs
and 4 and drain all the
oil
• Clean the magnetic stoppers on the oil drain plugs
and renew all the sealing rings
Fitting a new oil filter element (each time the oil is
changed)
• Put an oil pan or similar underneath
• Unscrew and remove mounting bolt
5
Danger of burns!
There is still oil in the filter housing.
6
• Pull the filter cover
with attached filter 8 out of
the fixture
• Pull the filter element
8
off the filter cover
6
• Remove the magnetic disc 9 from the used filter,
clean it and affix it to the new filter using grease
9
Note: Fit a magnetic disc
if one is not already
fitted.
7
• Renew the O-ring
on the filter cover and apply
grease
1
• Apply grease on the O-ring
on the new filter
element
8
• Place a new filter element
cover
6
onto the filter
• Screw in and tighten the filter cover mounting bolt
5
Tightening torque
5
Oil filter mounting bolt
.............................. 23 Nm
2.21 - 2WA 74 (3rd)
MAN ComfortShift MANUAL GEARBOX with INTARDER
Filling with oil
1
2
The decisive factors in obtaining the required oil
quantity are filling the oil correctly and performing the
oil level check precisely.
see........................Type plate, "Technical Data" or
"Maintenance Recommendations and
Recommended Service Products" booklet.
Danger of damage!
Ensure that the thread for the oil drain
2
plug
in the gearbox housing is
absolutely clean!
• Fit new seals on the oil drain plugs, screw them in
and tighten them
• Unscrew and remove oil filler plug
1
• Pour in oil through the filler and checking hole until
it reaches the bottom edge of the hole or starts
flowing out of the hole
• Fit a new sealing ring on the oil filler plug
• Screw in and tighten the oil filler plug
Note: There is an oil change notice
1
plug
. Do not remove this notice from the oil
2
on the oil filler
filler plug.
• Perform a short test drive and check for correct
functioning of the Intarder
• Before completing the test drive, switch off the
Intarder and bring the vehicle to a standstill
without activating the Intarder
After the test drive:
• Recheck the oil level as described under
"Checking the oil level". If necessary, top up with
oil until the oil starts to overflow
Tightening torques
1
Oil filler plug
Oil drain plug
Oil drain plug
.........................................60 Nm
3
.......................................60 Nm
4
.....................................120 Nm
GEARBOX BREATHER
Note: The following procedure does not apply to
vehicles with semilifetime oil fill.
Correct functioning of the breather valve must be
guaranteed at all times.
Cleaning
The breather must be kept clean. Make sure the
plastic cap is removed.
• In the event of dirt build-up, clean the outside of
breather (à) on the top of the gearbox
Note: Do not use high-pressure cleaners to clean
the breather.
WA 74 (3rd)2.21 - 3
MAN ComfortShift MANUAL GEARBOX with POWER TAKE-OFF
MAN ComfortShift MANUAL GEARBOX with
3
2
1
POWER TAKE-OFF (NMV 221)
16-speed manual gearbox and flange-mounted
engine-dependent power take-off NMV 221. The
manual gearbox and the engine-dependent power
take-off share the same oil circuit.
Correct functioning of the breather valve must be
guaranteed at all times.
Cleaning
The breather must be kept clean. Make sure the
plastic cap is removed.
• In the event of dirt build-up, clean the outside of
breather (à) on the top of the gearbox
Note: Do not use high-pressure cleaners to clean
the breather.
WA 74 (3rd)2.22 - 3
MAN TipMatic AUTOMATIC GEARBOX
MAN TipMatic AUTOMATIC GEARBOX
2
1
(ZF ASTRONIC 12 AS …)
The ZF ASTRONIC gearboxes are manual
gearboxes with a fully automatic shift system. This
means the gears are shifted electro-pneumatically
and there is no need for the driver to use the clutch
(no clutch pedal). The gearbox can be operated in
either automatic mode or manual mode (see
Operator's Manual).
GEARBOX BREATHER (not illustrated)
Note: The following procedure does not apply to
vehicles with semilifetime oil fill.
Correct functioning of the breather valve must be
guaranteed at all times.
Cleaning
The breather must be kept clean. Make sure the
plastic cap is removed.
• In the event of dirt build-up, clean the outside of
4
breather
on the top of the gearbox
Note: Do not use high-pressure cleaners to clean
the breather.
2.30 - 2WA 74 (3rd)
MAN TipMatic AUTOMATIC GEARBOX with INTARDER
MAN TipMatic AUTOMATIC GEARBOX with
1
INTARDER (ZF 12 AS ...)
The ZF ASTRONIC gearboxes are manual
gearboxes with a fully automatic shift system. This
means the gears are shifted electro-pneumatically
and there is no need for the driver to use the clutch
(no clutch pedal). The gearbox can be operated in
either automatic mode or manual mode (see
Operator's Manual).
Do not operate the Intarder immediately before
stopping the vehicle to check the oil level. This
ensures that the correct quantity of oil is set in the
gearbox.
Do not check the oil level immediately after driving
(incorrect reading). Only check once the gearbox has
cooled down.
Note: Each time you check the oil, also check the
gearbox, Intarder, oil/water heat exchanger
and their coolant pipes for possible leaks.
• Park the vehicle on a flat, level surface
• Stop the engine
• Put an oil pan or similar underneath
• Unscrew and remove oil filler plug
1
The oil must reach the bottom edge of the checking
and filler hole. Top up until oil overflows, if
necessary.
Do not operate the Intarder immediately before
stopping the vehicle to change the oil! This ensures
that the correct oil drain quantity is set in the
gearbox.
Note: Each time you change the oil, renew the oil
filter (see below) and, in the case of vehicles
with semilifetime oil fill, renew the breather,
see section 2.49.
Draining the oil
2
• Unscrew and remove oil drain plugs
3
drainage point) and
(Intarder housing drainage
(gearbox
point) and drain all the oil
• Clean the magnetic stoppers on the oil drain plugs
and renew all the sealing rings
• Take out the used filter and insert a new one
Fitting a new oil filter element (each time the oil is
changed)
• Put an oil pan or similar underneath
• Unscrew and remove mounting bolt (à)
Danger of burns!
There is still oil in the filter housing.
4
• Pull the filter cover
with attached filter 6 out of
the fixture
• Pull the filter element
6
off the filter cover
4
• Remove the magnetic disc 7 from the used filter,
clean it and affix it to the new filter using grease
7
Note: Fit a magnetic disc
if one is not already
fitted.
5
• Renew the O-ring
on the filter cover and apply
grease
8
• Apply grease on the O-ring
on the new filter
element
6
• Place new filter element
onto the filter cover
• Insert the filter cover and filter element into the
filter aperture and slide it in as far as the stop
• Screw in and tighten the filter cover mounting bolt
(à)
Tightening torque
Mounting bolt (à) for filter cover .................. 23 Nm
4
2.31 - 2WA 74 (3rd)
MAN TipMatic AUTOMATIC GEARBOX with INTARDER
Filling with oil
1
9
3
2
The decisive factors in obtaining the required oil
quantity are filling the oil correctly and performing the
oil level check precisely.
see........................Type plate, "Technical Data" or
"Maintenance Recommendations and
Recommended Service Products" booklet.
The decisive factors in obtaining the required oil
quantity are filling the oil correctly and performing the
oil level check precisely.
Danger of damage!
Ensure that the thread for the oil drain
2
plug
in the gearbox housing is
absolutely clean!
2
• Fit a new sealing ring on the oil drain plug
,
screw it in and tighten it
• Unscrew oil filler plug
1
• Pour in oil through filler and checking hole 1 until it
reaches the bottom edge of the hole or starts
flowing out of the hole
• Screw in and tighten the oil filler plug
Tightening torques
1
Oil filler plug
Oil drain plug
......................................20 – 27 Nm
2
....................................20 – 27 Nm
GEARBOX BREATHER
Correct functioning of the breather valve must be
guaranteed at all times.
Cleaning
The breather must be kept clean. Make sure the
plastic cap is removed.
• In the event of dirt build-up, clean the outside of
breather (â) on the top of the gearbox
Note: Do not use high-pressure cleaners to clean
the breather.
WA 74 (3rd)2.38 - 1
BREATHER FOR SEMILIFETIME OIL FILL
BREATHER FOR SEMILIFETIME OIL FILL
113
2
4
The breather and the PA pipelines (PA = polyamide
(plastic), 6x1 M3230) with connection system 203
(VOSS) must be renewed when changing the oil in
the gearbox and/or driven axle.
INSTALLATION POSITION
Gearbox:
1
− Breather
below the air filter housing
Axle:
− Breather
1
above the driven axle
RENEWING
Removing
• Mark the routing of the PA pipelines and the
position of the plastic fasteners
• Remove all the fasteners
• Undo the mounting bolts
2
3
on the breather
(illustrated example: axle)
• Unscrew the connection system union screw
the axle housing
4
on
WA 74 (3rd)2.49 - 1
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