MAN TGA Operator’s and Maintenance Manual

WA
Trucknology Generation A (TGA)
2003 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12
Maintenance Manual
81.99197– 4442 WA 74* (3.)
MAN Nutzfahrzeuge Aktiengesellschaft Wartungsanleitung WA 74 (3.) Dachauer Str. 667 oder Postfach 50 06 20 Trucknology Generation A (TGA) 80995 MÜNCHEN 80976 MÜNCHEN
–englisch–
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
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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 München Übersetzung + Satz: emes GmbH Druck: MAN–Werksdrucker
04.2003 – 0.23 Friedrichshafen DocuTech
TABLE OF CONTENTS
MAINTENANCE INSTRUCTIONS
General instructions...................................................................................................................... 0.40 - 1
Maintenance work......................................................................................................................... 0.40 - 1
NOTES ON SAFETY AND ENVIRONMENTAL PROTECTION
Notes on safety............................................................................................................................. 0.50 - 1
Environmental protection.............................................................................................................. 0.50 - 3
CHECKLIST FOR MAINTENANCE WORK
Acceptance sheet ......................................................................................................................... 0.60 - 1
Operation-specific work E, S6, S12.............................................................................................. 0.60 - 2
Lubrication service........................................................................................................................ 0.60 - 2
General technical safety ............................................................................................................... 0.60 - 3
Brake technical safety................................................................................................................... 0.60 - 3
Preventive inspection.................................................................................................................... 0.60 - 3
Checks and minor maintenance ................................................................................................... 0.60 - 4
Winter service............................................................................................................................... 0.60 - 4
Maintenance work for reconditioned engine................................................................................. 0.60 - 4
TECHNICAL DATA
Engines......................................................................................................................................... 0.70 - 1
Poly-V-belts................................................................................................................................... 0.70 - 2
Brake system................................................................................................................................ 0.70 - 2
Axles............................................................................................................................................. 0.70 - 2
Fill quantities................................................................................................................................. 0.70 - 3
Bulbs............................................................................................................................................. 0.70 - 4
Tyres and inflation pressure.......................................................................................................... 0.70 - 5
Reference torques ........................................................................................................................ 0.70 - 6
ENGINE
Cylinder head bolts....................................................................................................................... 1.00 - 1
D2866 LF / D2876 LF – four-valve engine, without EVB
Valve clearance ............................................................................................................................ 1.10 - 1
Retightening the injector nozzle pressure flange nuts (first service)............................................. 1.10 - 4
Valve clearance (alternative method) ........................................................................................... 1.10 - 5
D2866 LF / D2876 LF – four-valve engine, with EVB
Valve clearance ............................................................................................................................ 1.11 - 1
Retightening the injector nozzle pressure flange nuts (first service)............................................. 1.11 - 5
Valve clearance (alternative method) ........................................................................................... 1.11 - 6
D0836 LF – four-valve engine, with EVB
Valve clearance ............................................................................................................................ 1.12 - 1
Valve clearance (alternative method) ........................................................................................... 1.12 - 5
Changing engine oil and fitting a new filter
Changing engine oil and fitting a new filter................................................................................... 1.20 - 1
Oil level......................................................................................................................................... 1.20 - 4
Topping up the oil ......................................................................................................................... 1.20 - 6
INTAKE SYSTEM
Dry air filter
Filter element.............................................................................................................................. 1.60 - 1
WA 74 (3rd) 0.30 - 1
TABLE OF CONTENTS
COOLING AND HEATING SYSTEM
Condition, correct functioning and leak-tightness......................................................................... 1.70 - 1
Insect screen and radiator fins ..................................................................................................... 1.70 - 1
Hose clamps................................................................................................................................. 1.70 - 1
Coolant change ............................................................................................................................ 1.70 - 2
Coolant mixing ratio...................................................................................................................... 1.70 - 4
Antifreeze (to MAN 324)............................................................................................................. 1.70 - 4
Corrosion protection agent (to MAN 248) .................................................................................. 1.70 - 5
Pressure-relief valve on the expansion tank................................................................................. 1.70 - 6
Dust filter ...................................................................................................................................... 1.70 - 6
Coolant level................................................................................................................................. 1.70 - 7
Topping up the coolant................................................................................................................. 1.70 - 7
POLY-V BELTS
D2866 LF / D2876 LF
Condition.................................................................................................................................... 1.80 - 1
Tension ...................................................................................................................................... 1.80 - 1
Renewing................................................................................................................................... 1.80 - 2
D0836 LF
Condition.................................................................................................................................... 1.80 - 3
Renewing................................................................................................................................... 1.80 - 3
FUEL SYSTEM
Testing.......................................................................................................................................... 1.90 - 1
Cleaning ....................................................................................................................................... 1.90 - 1
Fuel service centre
Fine-mesh filter .......................................................................................................................... 1.90 - 1
Bleeding the fuel system............................................................................................................ 1.90 - 1
Bleeding the common-rail system.............................................................................................. 1.90 - 2
Main filter...................................................................................................................................... 1.90 - 3
Fuel pre-filter ................................................................................................................................ 1.90 - 4
Auxiliary heater............................................................................................................................. 1.90 - 5
CLUTCH
Fluid level ..................................................................................................................................... 2.10 - 1
Correct functioning ....................................................................................................................... 2.10 - 1
Wear............................................................................................................................................. 2.10 - 1
MAN ComfortShift MANUAL GEARBOX (ZF 16 S ...)
Oil level......................................................................................................................................... 2.20 - 1
Oil change .................................................................................................................................... 2.20 - 1
Breather........................................................................................................................................ 2.20 - 2
MAN ComfortShift MANUAL GEARBOX with INTARDER (ZF 16 S ...)
Oil level......................................................................................................................................... 2.21 - 1
Oil change .................................................................................................................................... 2.21 - 2
Oil filter ......................................................................................................................................... 2.21 - 2
Breather........................................................................................................................................ 2.21 - 3
MAN ComfortShift MANUAL GEARBOX with POWER TAKE-OFF (NMV 221)
Oil level......................................................................................................................................... 2.22 - 1
Oil change .................................................................................................................................... 2.22 - 1
Oil filter ......................................................................................................................................... 2.22 - 2
Breather........................................................................................................................................ 2.22 - 3
MAN TipMatic AUTOMATIC GEARBOX (ZF 12 AS ...)
Oil level......................................................................................................................................... 2.30 - 1
Oil change .................................................................................................................................... 2.30 - 1
Breather........................................................................................................................................ 2.30 - 2
0.30 - 2 WA 74 (3rd)
TABLE OF CONTENTS
MAN TipMatic AUTOMATIC GEARBOX with INTARDER (ZF 12 AS ...)
Oil level......................................................................................................................................... 2.31 - 1
Oil change..................................................................................................................................... 2.31 - 2
Breather........................................................................................................................................ 2.31 - 3
EATON FSO 8309 MANUAL GEARBOX
Oil level......................................................................................................................................... 2.38 - 1
Oil change..................................................................................................................................... 2.38 - 1
Breather........................................................................................................................................ 2.38 - 1
BREATHER FOR SEMILIFETIME OIL FILL
Installation position ....................................................................................................................... 2.49 - 1
Renewing...................................................................................................................................... 2.49 - 1
ZF 5/6 HP ... AUTOMATIC GEARBOX
Oil level
Main oil level check .................................................................................................................... 2.50 - 1
Preliminary oil level check.......................................................................................................... 2.50 - 1/2
Changing the oil and fitting a new filter......................................................................................... 2.50 - 2
G 172 / 173 TRANSFER CASE
Oil level......................................................................................................................................... 2.75 - 1
Oil change..................................................................................................................................... 2.75 - 1
NON-DRIVEN AXLES FRONT, LEADING AND TRAILING AXLE
Front axle steering knuckle........................................................................................................... 3.10 - 1
End play........................................................................................................................................ 3.10 - 1
HYPOID REAR AXLE HY – 1350
Oil level......................................................................................................................................... 3.20 - 1
Oil change..................................................................................................................................... 3.20 - 1
DRIVEN FRONT AXLE VP – 09
Axle centre drive
Oil level....................................................................................................................................... 3.25 - 1
Oil change.................................................................................................................................. 3.25 - 1
Planetary hub drive
Oil level....................................................................................................................................... 3.25 - 2
Oil change.................................................................................................................................. 3.25 - 2
Steering knuckle bearings
Oil level....................................................................................................................................... 3.25 - 3
Clearance................................................................................................................................... 3.25 - 3
PLANETARY REAR AXLE HP – 1352
Axle centre drive
Oil level....................................................................................................................................... 3.30 - 1
Oil change.................................................................................................................................. 3.30 - 1
Planetary hub drive
Oil level....................................................................................................................................... 3.30 - 2
Oil change.................................................................................................................................. 3.30 - 2
PLANETARY REAR AXLE HPD – 1382
Power divider
Oil level....................................................................................................................................... 3.31 - 1
Oil change.................................................................................................................................. 3.31 - 1
Planetary hub drive
Oil level....................................................................................................................................... 3.31 - 2
Oil change.................................................................................................................................. 3.31 - 2
WA 74 (3rd) 0.30 - 3
TABLE OF CONTENTS
PLANETARY REAR AXLE H9 – 13120
Axle centre drive
Oil level ...................................................................................................................................... 3.32 - 1
Oil change.................................................................................................................................. 3.32 - 1
Planetary hub drive
Oil level ...................................................................................................................................... 3.32 - 2
Oil change.................................................................................................................................. 3.32 - 2
PLANETARY REAR AXLE HD9
Power divider
Oil level ...................................................................................................................................... 3.33 - 1
Oil change.................................................................................................................................. 3.33 - 1
Planetary hub drive
Oil level ...................................................................................................................................... 3.33 - 2
Oil change.................................................................................................................................. 3.33 - 2
PROPSHAFTS
Propshaft flange ........................................................................................................................... 3.70 - 1
Balancing plate(s)......................................................................................................................... 3.70 - 1
Sliding section and universal joint................................................................................................. 3.70 - 1
Bearing bushes............................................................................................................................. 3.70 - 1
Intermediate bearing..................................................................................................................... 3.70 - 1
STEERING SYSTEM
Steering and starter lock............................................................................................................... 4.10 - 1
Power steering system ................................................................................................................. 4.10 - 1
Fluid level ..................................................................................................................................... 4.10 - 1
Rear axle steering system............................................................................................................ 4.10 - 2
Steering play................................................................................................................................. 4.10 - 3
Drag links and track rods.............................................................................................................. 4.10 - 3
Ball joints...................................................................................................................................... 4.10 - 3
Sealing bellows............................................................................................................................. 4.10 - 3
Drop arm nut................................................................................................................................. 4.10 - 3
COMPRESSED AIR SYSTEM
Air dryer........................................................................................................................................ 5.10 - 1
Air dryer granulate cartridge......................................................................................................... 5.10 - 2
Granulate cartridge – ECAM ........................................................................................................ 5.10 - 3
BRAKE TECHNICAL SAFETY
Visual inspection of the brake system .......................................................................................... 5.20 - 1
Checking correct functioning and effectiveness of the brake system........................................... 5.20 - 1
Disc brake..................................................................................................................................... 5.20 - 1
Drum brake................................................................................................................................... 5.20 - 1
Greasing the yoke end/brake lever............................................................................................ 5.20 - 2
Lubricating the slack adjuster/brake shaft bearing..................................................................... 5.20 - 2
ENGINE BRAKE
Butterfly ........................................................................................................................................ 5.50 - 1
BATTERIES
Electrolyte level............................................................................................................................. 6.10 - 1
Terminals...................................................................................................................................... 6.10 - 1
Charge level ................................................................................................................................. 6.10 - 1
Load and no-load voltage............................................................................................................. 6.10 - 2
Notes on safety when handling batteries...................................................................................... 6.10 - 3
0.30 - 4 WA 74 (3rd)
TABLE OF CONTENTS
HEADLIGHTS
General information ...................................................................................................................... 6.20 - 1
Adjusting....................................................................................................................................... 6.20 - 1
Main headlights............................................................................................................................. 6.20 - 3
Auxiliary headlights....................................................................................................................... 6.20 - 4
TYRES
Tyres............................................................................................................................................. 6.30 - 1
Tyre inflation pressure and tyre condition..................................................................................... 6.30 - 2
Wheel nuts.................................................................................................................................... 6.30 - 2
Spare wheel mounting.................................................................................................................. 6.30 - 3
CAB
Hydraulic system, checking/topping up the oil level...................................................................... 7.10 - 1
Tilting and locking mechanism...................................................................................................... 7.10 - 1
Roof spoiler/aerodynamic package............................................................................................... 7.10 - 2
CHASSIS
Leaf suspension............................................................................................................................ 7.20 - 1
Tandem axle (parabola/trapezium)............................................................................................... 7.20 - 2
Supporting structure for swap body.............................................................................................. 7.20 - 3
Air suspension .............................................................................................................................. 7.20 - 3
BEKA–MAX CENTRAL LUBRICATION SYSTEM
Lubricant level............................................................................................................................... 7.82 - 1
Lubricant tank ............................................................................................................................... 7.82 - 1
Correct functioning........................................................................................................................ 7.82 - 2
Troubleshooting chart, "fault – cause – remedy".......................................................................... 7.82 - 3
ROCKINGER TRAILER COUPLING
Cleaning........................................................................................................................................ 8.10 - 1
Lubricating .................................................................................................................................... 8.10 - 1
Correct functioning........................................................................................................................ 8.10 - 1
Wear ............................................................................................................................................. 8.10 - 2
Condition and firm seating............................................................................................................ 8.10 - 3
Play-free trailer coupling............................................................................................................... 8.10 - 4
RINGFEDER TRAILER COUPLING
Cleaning........................................................................................................................................ 8.11 - 1
Lubricating .................................................................................................................................... 8.11 - 1
Correct functioning........................................................................................................................ 8.11 - 1
Wear ............................................................................................................................................. 8.11 - 2
Condition and firm seating............................................................................................................ 8.11 - 3
FISCHER FIFTH WHEEL COUPLING
Cleaning........................................................................................................................................ 8.20 - 1
Lubricating .................................................................................................................................... 8.20 - 1
Condition....................................................................................................................................... 8.20 - 1
Wear ............................................................................................................................................. 8.20 - 2
Firm seating.................................................................................................................................. 8.20 - 4
Locking mechanism...................................................................................................................... 8.20 - 5
Correct functioning........................................................................................................................ 8.20 - 6
WA 74 (3rd) 0.30 - 5
TABLE OF CONTENTS
JOST FIFTH WHEEL COUPLING
Cleaning ....................................................................................................................................... 8.21 - 1
Lubricating.................................................................................................................................... 8.21 - 1
Condition ...................................................................................................................................... 8.21 - 2
Wear............................................................................................................................................. 8.21 - 2
Firm seating.................................................................................................................................. 8.21 - 4
Mounting....................................................................................................................................... 8.21 - 5
Locking function............................................................................................................................ 8.21 - 6
Interlock........................................................................................................................................ 8.21 - 6
Locking mechanism...................................................................................................................... 8.21 - 7
Correct functioning ....................................................................................................................... 8.21 - 7
ROCKINGER FIFTH WHEEL COUPLING
Cleaning ....................................................................................................................................... 8.22 - 1
Lubricating.................................................................................................................................... 8.22 - 1
Condition ...................................................................................................................................... 8.22 - 1
Wear............................................................................................................................................. 8.22 - 2
Firm seating.................................................................................................................................. 8.22 - 3
Mounting....................................................................................................................................... 8.22 - 3
Coupling lock................................................................................................................................ 8.22 - 4
Correct functioning ....................................................................................................................... 8.22 - 4
HOLLAND EUROPE FIFTH WHEEL COUPLING
Cleaning ....................................................................................................................................... 8.23 - 1
Lubricating.................................................................................................................................... 8.23 - 1
Condition ...................................................................................................................................... 8.23 - 2
Wear............................................................................................................................................. 8.23 - 3
Firm seating.................................................................................................................................. 8.23 - 3
Locking mechanism...................................................................................................................... 8.23 - 4
Correct functioning ....................................................................................................................... 8.23 - 6
TIPPER SYSTEM
General information...................................................................................................................... 8.40 - 1
Condition and firm seating............................................................................................................ 8.40 - 2
Lubricating.................................................................................................................................... 8.40 - 2
Tipper body
Tipping boom ............................................................................................................................. 8.40 - 3
Automatic side wall latch .............................................................................................................. 8.40 - 3
"Bordmatik" automatic unloading system .................................................................................... 8.40 - 3
Rear wall latch.............................................................................................................................. 8.40 - 3
Subframe
Tipping member......................................................................................................................... 8.40 - 4
Hydraulic system
Lower press mounting................................................................................................................ 8.40 - 5
Shut-off valve linkage shaft........................................................................................................ 8.40 - 5
Upper press mounting................................................................................................................ 8.40 - 5
Hydraulic oil change ..................................................................................................................... 8.40 - 6
Oil level......................................................................................................................................... 8.40 - 7
AIR-CONDITIONING SYSTEM
Condenser.................................................................................................................................... 8.90 - 1
MAINTENANCE SYSTEM
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 - 6 WA 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
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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 - 2 WA 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
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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 - 2 WA 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.
km Years
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
Antifreeze checked
°C
Job completed on (date)
Job completed by
CHECKLIST FOR MAINTENANCE WORK
Customer Licence plate number
Vehicle type
Customer signature Vehicle ident. no.
Current mileage/km
that are due
Engine o Gearbox om S6 o
Driven axle(s) oq S12 o Transfer case
Separate oil circuit o
oil is changed
Engine:Renew engine oil filter element o
Renew fuel filter element o Clean fuel pre-cleaner filter o
Renew filter element o
Renew filter element o
o
ü
that is due
² First service o
Winter service
ü
that is due
o
ü
(km or date)
inspection (SP) is performed
Separate job o
–2
200,000 2
500,000 4
ü
Clean oil drain strainer o
Renew filter element o
Renew breather o
Clean filter element
Checklist pages 1 - 4: Tick work that has been completed (ü)!
Maintenance system ... Operator's Manual
Service products .......... Recommended Service Products
Fill quantities ............... Operator's Manual
Maintenance Manual
Maintenance work ....... Maintenance Manual
Confirmation ................ Maintenance Record
Filing of checklist ......... File with job
completing work!
o
200,000 2
....................................................................
Oil drain plugs tightened ...........................................................
Oil topped up, oil level checked ................................................
Wheel nuts tightened ................................................................
Vehicle operational ...................................................................
.........................................................................
.........................................................................
WA 74 (3rd) 0.60 - 1
MAN ProFit-Check TGA Trucks
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)
E S 6 S 12
² ²
mq
mq
²
² ²
q
q
q
q
q
q
q
q
q
q
q
heavy) Auxiliary air and/or water heater: Fuel supply filter
Separ fuel pre-filter: Filter element
LUBRICATION SERVICE
LUBRICATE USING AN OIL CAN OR GREASE
Linkages, cables, joints, bearings, hinges, catches
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)
q
q
q
E S 6 S 12
mq
mq
mq
mq
mq
mq
q
q
q
q
0.60 - 2 WA 74 (3rd)
MAN ProFit-Check TGA Trucks
May be omitted if maintenance and statutory safety inspection are performed by MAN Service
CHECK: Condition, correct functioning, effectiveness, leak-tightness, routing, damage, corrosion,
BRAKE TECHNICAL SAFETY
May be omitted if maintenance and statutory safety inspection are performed by MAN Service
Condition, leak-tightness, routing, damage, corrosion, chafing, pad/lining and brake disc/brake drum
CHECK: Condition, correct functioning, effectiveness, leak-tightness, routing, damage, corrosion,
Cooling and heating system, radiator insect screen; also dirt in air-conditioning condenser and fins in
GENERAL TECHNICAL SAFETY
at the same time.
chafing Engine, gearbox, retarder, driven axles, shock absorbers (visual inspection)
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
E S 6 S 12
² ² ² ²
mq
mq
mq
mq
mq
mq
q
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)
² ² ² ² ²
E S 6 S 12
mq
mq
mq
mq
mq
mq
E S 6 S 12
²
²
mq
mq ²q ²q ²q
mq
mq
mq
q q q q
² ² ²
WA 74 (3rd) 0.60 - 3
MAN ProFit-Check TGA 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
E S 6 S 12
mq mq mq mq mq mq mq
² ² ² ²
mq
mq
mq
mq
q q q q q q q
Maintenance work for reconditioned 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.
Work, maintenance points
CHECK: Condition, correct functioning, effectiveness, leak-tightness, routing, damage, corrosion, chafing
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 - 4 WA 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 sequence 1–5–3–6–2–4
Engine model (EURO 3)
Firing sequence 1–5–3–6–2–4
Engine model (EURO 2)
Firing sequence 1–5–3–6–2–4
to ISO 1585–88/195 EEC
WA 74 (3rd) 0.70 - 1
TECHNICAL DATA
POLY-V BELTS
V-belt tension.................................Set using gauge
2
Reservoir pressures:
Circuit 1
12.5 ±0.3
12.5 ± 0.2
Circuit 2
12.5 ± 0.2
Circuit 3
8.5 -0.5
8.5 -0.4
Circuit 4
10.0 ± 0.3
12.5 ± 0.2
Operating pressure:
Service brake system
10.0
10.0
Parking brake system
8.5 -0.5
8.5 -0.4
Trailer brake
8.5 -0.5
8.5 -0.4
AXLES
A
l w T t
F V
V N
N
M
R H
H H
in
k
H H
r
D2866 and D2876
Designation
with refrigerant compressor...... 8 K 1376 SK 534
without refrigerant compressor .. 8 K 880 SK 534
D0836
Designation...........................................8 PK 1275
BRAKE SYSTEM (pressures in bar)
Shut-off pressure: 12.5 ±0.3 12.5 ± 0.
Operating range:
ECAM Air dryer
2.0 -0.3 1.3 +0.7
12.5 ±0.3
ll axles are fitted with disc brakes and an electrica ear indicator.
he wheel bearings are lubricated with high-
emperature grease and require no maintenance.
ront axle, trailing axle
P – 09 .........Driven planetary axle (AP) with disc
brake
OK – 08 ......Non-driven front axle with offset axle
housing; with air or leaf suspension
O – 08.........Lifting trailing axle with air
suspension; axle housing configured as tubular axle
OL – 08.......Lifting, steering trailing axle with air
suspension; axle housing configured as tubular axle
ax. play on steering knuckle
VOK– 08, NOL– 08...................................0.4 mm
10.0 ±0.3
Air suspension: 12.5 ±0.3
− ≤
Engine brake
Electro-pneumatically-operated engine brake valve.
Wheel brake Disc brake:
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 - 2 WA 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
VP – 09...............................................................9.2
Centre drive.....................................................6.0
Planetary drive........................................... 2 x 1.5
Steering knuckle......................................2 x 0.05
Transfer case G 172 / 173
with permanent front-axle drive .......................5.8
with non-permanently engaged front-axle drive..7.0
Power steering.....................................approx. 4.0
Power steering with emergency
steering pump......................................approx. 6.0
Hydraulically steering trailing axle
..................................................approx. 4.5 to 6.0
Hydraulically steering leading axle
..................................................approx. 4.0 to 6.0
Windscreen washers......................................15.0
Headlight cleaning system ............................10.0
Gearbox
MAN TipMatic automated manual gearbox
ZF – Astronic 12 AS 2301 .............................11.0
ZF – Astronic 12 AS 2301 + Intarder.............12.0
MAN ComfortShift manual gearbox
ZF 16 S 151....................................................8.0
ZF 16 S 151 OD/DD.......................................9.0
ZF 16 S 151 + Intarder ................................. 11.0
1)
ZF 16 S 181..................................................10.0
ZF 16 S 181 + Intarder .................................12.0
ZF 16 S 221.................................................. 10.0
1)
ZF 16 S 221 + Intarder ................................. 12.0
1)
1)
with separately mounted heat exchanger
..........................................................approx. +2.0
Automatic gearbox (the dipstick gives the most accurate measurement)
ZF – 5/6 HP.......................................12.0 to 17.0
with additional oil filter ............approx. +4.0 to 5.0
Eaton manual gearbox
Eaton FSO 8309.................................approx. 8.5
Power take-off
NMV....................................................approx. 2.0
NH ......................................................approx. 0.5
Eaton 2900.........................................approx. 1.0
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.
uel tank, depending on vehicle type
Steel .................................................220/300/400
Aluminium.....250/300/330/400/450/480/580/590/
600/700/710/780/800/910
Plastic...............................................................30
ombination tank (aluminium)....................200/400
ngine with oil filter
D2866 / D2876 – green dipstick
Total oil quantity ..........................................42.0
Dipstick "Max – Min"......................................6.0
D2866 / D2876 – red dipstick
Total oil quantity ..........................................33.0
Dipstick "Max – Min"......................................6.0
D0836
Total oil quantity ..........................................27.5
Dipstick "Max – Min"......................................5.0
ooling system including heating
ithout Intarder
D2866, D2876 and D0836.............................50.0
ith Intarder
D2866, D2876 and D0836.............................58.0
ith PriTarder
D2876............................................................52.0
Ensure that the coolant composition is as specifie in order to prevent PriTarder damage!
ear axle
Y – 1350:
Centre drive...................................................14.5
Wheel hub .................................2 x 100 g grease
P – 1352.........................................................15.8
Centre drive...................................................12.0
Planetary drive........................................... 2 x 1.9
PD – 1382:
Centre drive/through-drive.............................14.5
Planetary drive........................................... 2 x 1.9
DY – 1175......................................................15.4
Centre drive/through-drive.............................14.0
Planetary drive........................................... 2 x 0.7
9 – 1180 / 1380..............................................16.0
Centre drive.....................................................9.0
Planetary drive........................................... 2 x 3.5
D9 – 1180/1380..............................................20.0
Centre drive...................................................11.0
Transfer drive ..................................................2.0
Planetary drive........................................... 2 x 3.5
WA 74 (3rd) 0.70 - 3
TECHNICAL DATA
Power take-off
NMV....................................................approx. 2.0
A
B
H
T B T M F
P R D E O I G S
NH.......................................................approx. 0.5
Eaton 2900 .........................................approx. 1.0
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 - 4 WA 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 22,5 7.5 7.5 7.75 7.75 8.0 8.0 8.5 –––– 3 R 22,5 / K 6.5 6.75 6.75 7.0 7.0 7.25 7.5 8.0 – 3 R 22,5 / L 6.5 6.75 6.75 7.0 7.0 7.0 7.5 8.0 8.5 – 85/60 R 22,5 9.0 ––––––––– 95/60 R 22,5 8.75 9.0 9.0 –––––––– 05/60 R 22,5 8.5 8.5 8.75 8.75 9.0 –––––– 15/60 R 22,5 8.0 8.0 8.0 8.25 8.25 8.25 9.0 –––– 85/65 R 22,5 6.5 6.5 6.75 7.0 7.5 8.0 8.5 9.0 75/70 R 22,5 9.0 ––––––––– 05/70 R 22,5 8.0 8.0 8.25 8.25 8.5 –––––– 15/70 R 22,5 7.5 7.5 7.75 7.75 8.0 8.25 8.5 9.0 – 95/80 R 22,5 7.5 7.5 7.75 7.75 8.0 8.25 8.5 –––– 15/80 R 22,5 7.0 7.25 7.25 7.5 7.5 7.75 8.0 8.5
2 R 22,5 5.75 6.25 6.75 7.25 7.5 7.75 8.0 – 3 R 22,5 / K 5.5 5.75 6.5 6.75 6.75 7.25 7.75 3 R 22,5 / L 5.5 5.75 6.25 6.75 7.0 7.25 7.5 8.25 85/60 R 22,5 7.0 7.5 8.0 8.25 8.5 9.0 – 95/60 R 22,5 7.0 7.5 8.25 8.5 8.5 9.0 – 05/60 R 22,5 7.25 8.0 8.25 8.25 8.5 – 15/60 R 22,5 7.25 7.5 7.75 8.0 – 85/65 R 22,5 –––––– 75/70 R 22,5 7.75 8.0 8.25 8.5 – 05/70 R 22,5 6.5 7.0 7.25 7.5 7.75 – 15/70 R 22,5 6.75 7.0 7.25 7.5 8.25 95/80 R 22,5 6.5 7.25 7.5 7.75 8.0 – 15/80 R 22,5 6.5 6.5 6.75 7.0 7.75
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
xle load (kg) 6300 6400 6500 6600 6700 6800 7100 7500 8000 8500 9000
yres
yre inflation pressure (in bar with tyres cold) Twin tyres
xle load (kg) 9000 9500 10000 11000 11300 11500 12000 13000
yres
WA 74 (3rd) 0.70 - 5
REFERENCE TORQUES
U-bolts
Thread
Hot-formed
Cold-formed
M 14 x 1.5
185
165
M 16 x 1.5
210
225
M 18 x 2
280
330
M 20 x 2
400
440
M 24 x 2
680
800
M 27 x 2 1)900
1000
TIGHTENING TORQUES in Nm D
2866/76 engine
2 C R n L O O F
1
C
E S B S
1
2
D
P
C S S T M F C F
D
H
H
R H
H
H
nd retightening of cylinder head bolts.............. 90°
ylinder head cover.............................................22
etightening of pressure flange collar nut for
ozzle holder (for D28 4-valve engine) 1)........... 90°
ock nut on valve adjustment screw....................45
il drain plug........................................................80
il filter cover.......................................................25
uel filter cover ....................................................25
)
omitted in case of common-rail engine D2876 LF 12/13
ooling system
ntire cooling system
tandard part M3259 (belt width 12 mm).....5.0 Nm
reather line on expansion tank:
tandard part M7.751-30 (belt width 9 mm).... 3.5 Nm
)
also see Service Information 33900b dated
08.07.2002
)
with the exception of breather line on expansion tank
rain plug
on radiator......................................................4 +1
on ZF–Intarder..................................................35
on Voith retarder...............................................20
oly-V-belts
ollar bolts (WAF13)............................................35
pring damper element (WAF17)........................43
pring damper element (WAF13)........................22
ensioner (WAF10)..............................................50
ounting bolt (WAF22)......................................150
an.......................................................................45
able clamp.........................................................22
an clutch ............................................................45
28 / D08 fuel system
ousing cover
Pre-cleaner .......................................................25
Main filter ..........................................................25
Separ pre-filter..................................................15
and pump plunger ..........................................4 ±2
1,2)
Front axle VP – 09:
Axle centre drive
Oil filler and checking plug ...................100±10
Oil drain plug........................................100±10
Planetary hub drive
Oil filler, checking and drain plug .................95
Transfer case G 172 / 173
Oil filler plug.........................................................80
:
Oil drain plug........................................................80
Wheel nuts (including aluminium wheels) Disc wheel
Hub centring...............................................575 ± 25
Stud centring..............................................475 ± 25
U-bolts
U-bolt distinguishing features (hot-formed or cold­formed), see section 7.20 "CHASSIS".
1)
U-bolt 06.46115.XXXX (M27x2) only with ENKO®
lock nut 81.90685.0400
Air dryer
Desiccant cartridge:
Bosch...................................................................25
Knorr....................................................................25
Wabco..................................................................15
ear axle
Y – 1350:
Oil filler and checking plug................................70
Oil drain plug.....................................................70
P – 1352 / HPD – 1382:
Axle centre drive/power divider
Oil filler and checking plug ...................100±10
Oil drain plug........................................100±10
Planetary hub drive
Oil filler, checking and drain plug .................95
D/HD9 – 13120:
Axle centre drive/power divider
Oil filler and checking plug ...........................70
Oil drain plug................................................70
Planetary hub drive
M45x1.5 Aluminium cover..........................180
M45x1.5 Sheet-steel cover.........................325
Oil drain plug M24x1.5......................................80
0.70 - 6 WA 74 (3rd)
REFERENCE TORQUES
MAN TipMatic
O O O B
M
O O O I B
M
O O O I B
M
O O O I B
M
O O O O I B
E
O O B
Z
O O
B
M S
F
r M
(ZF 12 AS …)
il filler and checking plug...................................60
il drain plug (M 24)............................................60
il drain plug with magnetic stopper (M 38)......120
reather...............................................................10
AN TipMatic with Intarder (ZF 12 AS …)
il filler and checking plug...................................60
il drain plug (M 24)............................................60
il drain plug with magnetic stopper (M 38)......120
ntarder – oil filter mounting bolts.........................23
reather...............................................................10
AN ComfortShift (ZF 16 S …)
il filler and checking plug...................................60
il drain plug (M 24)............................................60
il drain plug with magnetic stopper (M 38)......120
ntarder-oil filter mounting bolt.............................23
reather...............................................................10
AN ComfortShift with Intarder (ZF 16 S …)
il filler and checking plug...................................60
il drain plug (M 24)............................................60
il drain plug with magnetic stopper (M 38)......120
ntarder-oil filter mounting bolt.............................23
reather...............................................................10
AN ComfortShift with NMV (ZF 16 S …)
il filler and checking plug...................................60
il filler plug, NMV...............................................60
il drain plug (M 24)............................................60
il drain plug with magnetic stopper (M 38)......120
ntarder-oil filter mounting bolts ...........................23
reather...............................................................10
aton FSO 8309 manual gearbox
il filler and checking plug...........................20 – 27
il drain plug................................................20 – 27
reather.......................................................16 – 22
F – 5/6 HP ... automatic gearbox
il drain plug........................................................50
il filter cover.......................................................25
reather for semilifetime oil fill
ounting bolt, breather........................................22
crew-in coupling:
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:
....................................................
....................................................
....................................................
....................................................
....................................................
..............................................
..................................................
.......................................
............................................
..................................................
.........................................
.......................................
..................................................
.........................................
..................................................
.........................................
..................................................
............................................
.........................................
..................................................
............................................
.........................................
..................................................
............................................
.........................................
..................................................
............................................
.........................................
............
............
............
..........
..........
..........
..........
..........
..........
..........
..........
..........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
.............
.............
...........
...........
...........
...........
...........
...........
...........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.......
0.70 - 8 WA 74 (3rd)
REFERENCE TORQUES
Bolt/nut with collar or flange head:
Smooth
Toothed or ribbed
Ribbed
Phosphated – black
Galvanised – yellow
Thread
10.9/10
100/10
12.9/12
10.9/10
1)
2)
1)
2)
1) 3)
1) 3)
M 5
11
M 6
19
M 8
45
M 8 x 1
M 10
95
M 10 x 1.25
M 10 x 1
M 12
115
150
170
M 12 x 1.5
120
150
170
120
150
M 12 x 1.25
125
M 14
175
260
320
M 14 x 1.5
190
260
320
210
280
M 16
280
360
425
M 16 x 1.5
300
360
425
270
370
M 18
380
M 18 x 2
400
520
4)
520 4)
M 18 x 1.5
420
550 4)
550 4)
M 20
540
M 20 x 2
560
M 20 x 1.5
590
M 22 x 2
740
M 22 x 1.5
780
Nm Nm
Nm
Nm
Nm
Nm
Nm
.................9...............10.........11........ –......... –..........8..........
.................15.............17.........19........ –......... –..........14........
.................35.............40.........45........ –......... –..........33........
...........40............. –.......... –......... –......... –.......... –.........
...............75.............85.........95........ –......... –..........70........
....75............. –.......... –......... –......... –.......... –.........
.........85............. –.......... –......... –......... –.......... –.........
...............
......
....
...............
......
...............
......
...............
.........
......
...............
.........
......
.........
......
1)
Value for tightening onto harder component materials such as C 45, quenched and tempered materials,
........... –.......... –.........
...........
.......
...... –......... –..........
......
....... –.........
......
........... –.......... –......... –......... –.......... –.........
........... –.......... –.........
...........
.......
...... –......... –..........
........... –.......... –.........
...........
.......
...... –......... –..........
......
......
....... –.........
......
....... –.........
......
........... –.......... –......... –......... –.......... –.........
........... –.......... –.........
........... –.......... –.........
...
... –.........
..
... –.........
........... –.......... –......... –......... –.......... –.........
........... –.......... –......... –......... –.......... –.........
........... –.......... –......... –......... –.......... –.........
........... –.......... –......... –......... –.......... –.........
........... –.......... –......... –......... –.......... –.........
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 - 10 WA 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 - 2 WA 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 / Intake 0.5 mm Auslass / Exhaust 0.6 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 - 2 WA 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
Tighten the lock nut
Re-check the valve clearance and adjust if
necessary
Tightening torque
Valve adjuster screw lock nut .....................45 Nm
Fitting the cylinder head cover
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
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 - 4 WA 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 - 2 WA 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
Tighten the lock nut
Re-check the valve clearance and adjust if
necessary
Tightening torque
Valve adjuster screw lock nut....................... 45 Nm
Exhaust valves (with EVB)
Desired valve clearance:
Exhaust valve bridge/rocker arm
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 - 4 WA 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 - 6 WA 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 - 2 WA 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 - 4 WA 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
Tightening torque
Oil filter cover................................................ 25 Nm
Engine D0836 LF (example illustrated for oil filter cover with oil filter element)
Filling with engine oil
After fitting a new sealing ring, insert and tighten
1
the oil drain plug
(example illustrated) on the oil
sump
Tightening torque
Oil drain plug ................................................ 80 Nm
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 - 2 WA 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
IN MAX
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.
Engine oil fill quantity and specification
see........................"Maintenance Recommendations
and Recommended Service Products“ booklet
MIN MAX
8
WA 74 (3rd) 1.20 - 3
ENGINE D2866 LF, D2876 LF, D0836 LF
Checking the engine oil level
I
I
9
9
I
II
Refer to Service Information (83900a dated
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 - 4 WA 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
IN MAX
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.
MIN MAX
1.20 - 6 WA 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 - 2 WA 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
Drain all the coolant
Screw in and tighten the drain plugs
3
and
4
Lower the cab
Tightening torques
3
Drain plug Drain plug
on radiator ........................... 4 - 5 Nm
4
on ZF-Intarder......................... 35 Nm
1.70 - 2 WA 74 (3rd)
COOLING AND HEATING SYSTEM
Filling with coolant
2
2
Coolant fill quantity and specification
see........................"Maintenance Recommendations
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 - 4 WA 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 - 6 WA 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.
Fit a new poly-V-belt
1.80 - 2 WA 74 (3rd)
POLY-V-BELTS
1
3
2
2
3
13
12
1
1
1
Insert and tighten the mounting bolts
for the fan
clutch
Insert and tighten the mounting bolt
1
for the cable
clamp
Tension the poly-V-belt (see page 1)
Tightening torques
1
Cable clamp Fan clutch
..............................................22 Nm
1
.................................................45 Nm
Lower the cab
POLY-V-BELT D0836 LF TENSION
The poly-V-belt is retensioned automatically.
CHECKING CONDITION
1
Check the poly-V-belts
for cracks, oily patches,
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 - 4 WA 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
3
Tightening torque
Housing cover...............................................25 Nm
Bleed the fuel system
Lower the cab
Bleeding the fuel system
Unscrew hand pump plunger
4
Pump the plunger until the overflow valve opens
Push down the hand pump plunger and screw it
firmly closed
Tightening torque
Plunger............................................................4 Nm
Example illustrated for CR engine D0836
WA 74 (3rd) 1.90 - 1
FUEL SYSTEM
Bleeding the common-rail fuel system
1
2
3
(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 - 2 WA 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
Tightening torque
Housing cover..................................................25 Nm
Bleed the fuel system
Lower the cab
WA 74 (3rd) 1.90 - 3
FUEL SYSTEM
Example illustrated for CR engine D0836
2
133
4
5
A
SEPAR FUEL PRE-FILTER Flushing the filter
The fuel level in the fuel tank must be higher than the
2
stopcock
.
Stop the engine
1
Remove hose
and bracket (MAN no.:
81.12540-6004) from the vehicle tool kit and screw it onto the drain cock fitting
Put a collecting container underneath
Open the bleed screw
Open the stopcock
A
2
Drain the condensation and impurities and dispose of them in the correct manner
Note: The fuel tank must be at least half full in order
to drain the condensation. There is a drainage point on the underside of the tank.
Close the bleed screw
Close stopcock
Pull off the hose
A
2
1
Renew filter element
Only fit RME-resistant filter elements and seals marked "FPM".
Stop the engine
Unscrew the mounting bolts
3
Remove the cover
Remove the spring housing
Renew the filter element
4
5
Insert the spring housing
Renew the cover gasket
Fit the cover and tighten the bolts
Tightening torque
Mounting bolts.............................................. 15 Nm
Check the filter for leaks
Bleed the fuel system if necessary (see Operator's
Manual)
1.90 - 4 WA 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
2
hole
Close the front flap
Specification
Clutch fluid........................................see
"Maintenance Recommendations and Recommended Service Products" booklet
CORRECT FUNCTIONING Checking
Start the engine and let it run at idling speed
Fully depress the clutch pedal
Slowly engage reverse gear after about 5 seconds
If reverse gear can be engaged without any gearshift noise (grating), this indicates that the clutch is separating completely.
WEAR Checking
Clutch adjustment is automatic. Read out the remaining clutch life using MAN-cats II.
WA 74 (3rd) 2.10 - 1
MAN ComfortShift MANUAL GEARBOX
MAN ComfortShift MANUAL GEARBOX
1
2
3
(ZF 16 S …) 16-speed manual gearbox with range-change and integrated splitter group
OIL LEVEL Checking (with gearbox cold, <40 °C)
Do not check the oil level immediately after driving (incorrect reading). Only check once the gearbox has cooled down.
Note: Check the gearbox for leaks each time you
check the oil.
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.
Fit a new sealing ring on the oil filler plug
Screw in and tighten the oil filler plug
Tightening torque
1
Oil filler plug
..............................................60 Nm
OIL CHANGE (with the gearbox at operating temperature)
Change the oil after a long drive whilst the gearbox oil is still at operating temperature and has low viscosity.
Note: In vehicles with semilifetime oil fill, always
renew the breather when changing the gearbox oil, see section 2.49.
Draining the oil
Put an oil pan or similar underneath
Danger of burns! Touching the gearbox or the gearbox oil can cause burns!
2
Unscrew oil drain plug
and 3 and drain all the
used oil
Clean the magnetic stoppers on the oil drain plugs
2
and renew all the sealing rings
WA 74 (3rd) 2.20 - 1
MAN ComfortShift MANUAL GEARBOX
Filling with oil
3
1
2
The decisive factors in obtaining the required oil quantity are filling the oil correctly and performing the oil level check precisely.
Gearbox oil specification
see........................"Maintenance Recommendations
and Recommended Service Products" booklet
Gearbox oil fill quantity
see........................Type plate, "Technical Data" or
"Maintenance Recommendations and Recommended Service Products" booklet.
Danger of damage! Ensure that the thread for the oil drain plug in the gearbox housing is absolutely clean!
3
Fit a new sealing ring on oil drain plugs
, screw
them in and tighten them
Unscrew and remove 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
Fit a new sealing ring on the oil filler plug
Screw in and tighten the oil filler plug
Tightening torques
1
Oil filler plug Oil drain plugs Oil drain plug
.............................................. 60 Nm
2
........................................ 120 Nm
3
............................................ 60 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.
2.20 - 2 WA 74 (3rd)
MAN ComfortShift MANUAL GEARBOX with INTARDER
MAN ComfortShift MANUAL GEARBOX with
1
2
INTARDER (ZF 16 S ...)
16-speed manual gearbox with range-change, integrated splitter group and integrated retarder system (Intarder)
OIL LEVEL Checking (with gearbox oil cold, <40 °C)
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.
2
Note: There is an oil change notice
1
plug
. Do not remove this notice from the oil
on the oil filler
filler plug.
Fit a new sealing ring on the oil filler plug
Screw in and tighten the oil filler plug
Tightening torque
1
Oil filler plug
..............................................60 Nm
WA 74 (3rd) 2.21 - 1
MAN ComfortShift MANUAL GEARBOX with INTARDER
OIL CHANGE (with the gearbox at operating
0
689105
4
3
7
6
temperature)
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 - 2 WA 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.
Gearbox oil specification
see........................"Maintenance Recommendations
and Recommended Service Products" booklet
Gearbox oil fill quantity
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.
OIL LEVEL Checking (with gearbox oil cold, <40 °C)
Do not check the oil level immediately after driving (incorrect reading). Only check once the gearbox has cooled down.
Note: Check the gearbox for leaks each time you
check the oil.
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.
Fit a new sealing ring on the oil filler plug
Screw in and tighten the oil filler plug
Tightening torque
1
Oil filler plug
..............................................60 Nm
OIL CHANGE (with the gearbox at operating temperature)
Change the oil after a long drive whilst the gearbox oil is still at operating temperature and has low viscosity.
Note: Each time you change the oil, renew the oil
filter (see next page) 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
2
Unscrew and remove oil drain plugs
and 3 and
drain all the oil
Clean the magnetic stopper on oil drain plug
2
and renew all the sealing rings
Take out the used filter and insert a new one
WA 74 (3rd) 2.22 - 1
MAN ComfortShift MANUAL GEARBOX with POWER TAKE-OFF
Fitting a new oil filter element (each time the oil is
475
4
5
4
6
changed)
Put an oil pan or similar underneath
Unscrew and remove the mounting bolts (à) from
the filter cover
4
Danger of burns! There is still oil in the filter housing.
4
Pull off the filter cover element
6
Renew the O-ring 5 on the filter cover
and remove the filter
4
and
apply grease
7
Apply grease on the O-ring
on the new filter
element
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 bolts (à)
Tightening torque
4
Mounting bolts for filter cover
................... 23 Nm
2.22 - 2 WA 74 (3rd)
MAN ComfortShift MANUAL GEARBOX with POWER TAKE-OFF
Filling with oil
1
8
1
The decisive factors in obtaining the required oil quantity are filling the oil correctly and performing the oil level check precisely.
Gearbox oil specification
see........................"Maintenance Recommendations
and Recommended Service Products" booklet
Gearbox oil fill quantity
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 sealing rings on oil filler plugs
2
and
3
(see page 1), screw them in and tighten them
Unscrew and remove oil filler plug
1
and
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
Pour in approx. 2 litres of oil through filler hole
8
Note: Filler hole 8 is not a checking hole.
Let the engine run at idling speed for about 3 minutes (gearbox in neutral, clutch engaged)
Stop the engine and pour in more oil through filler
1
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
Tightening torques
1
Oil filler plug Oil drain plug Oil drain plugs Oil filler plug
..............................................60 Nm
2
..........................................120 Nm
3
..........................................60 Nm
8
..............................................60 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) 2.22 - 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).
OIL LEVEL Checking (with gearbox oil cold, <40 °C)
Do not check the oil level immediately after driving (incorrect reading). Only check once the gearbox has cooled down.
Note: Check the gearbox for leaks each time you
check the oil.
Park the vehicle on a flat, level surface
Stop the engine
Put an oil pan or similar underneath
Unscrew and remove the oil filler plug
1
The oil must reach the bottom edge of the checking and filler hole. Top up until oil overflows, if necessary.
Fit a new sealing ring on the oil filler plug
Screw in and tighten the oil filler plug
Tightening torque
1
Oil filler plug
..............................................60 Nm
OIL CHANGE (with the gearbox at operating temperature)
Change the oil after a long drive whilst the gearbox oil is still at operating temperature and has low viscosity.
Note: In vehicles with semilifetime oil fill, always
renew the breather when changing the gearbox oil, see section 2.49.
Draining the oil
Put an oil pan or similar underneath
2
Unscrew and remove the oil drain plug
and
drain all the oil
Clean the magnetic stopper on the oil drain plug and fit a new sealing ring
2
WA 74 (3rd) 2.30 - 1
MAN TipMatic AUTOMATIC GEARBOX
Filling with oil
2
1
4
3
The decisive factors in obtaining the required oil quantity are filling the oil correctly and performing the oil level check precisely.
Gearbox oil specification
see........................"Maintenance Recommendations
and Recommended Service Products" booklet
Gearbox oil fill quantity
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 filler and checking hole 1 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
Tightening torques
1
Oil filler plug Oil drain plugs
.............................................. 60 Nm
2
and 3 .............................. 60 Nm
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 - 2 WA 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).
OIL LEVEL Checking (with gearbox oil cold, <40 °C)
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.
Fit a new sealing ring on the oil filler plug
Screw in and tighten the oil filler plug
Tightening torque
1
Oil filler plug
..............................................60 Nm
WA 74 (3rd) 2.31 - 1
MAN TipMatic AUTOMATIC GEARBOX with INTARDER
OIL CHANGE (with the gearbox at operating
3
2
6
4
7
485
temperature)
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 - 2 WA 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.
Gearbox oil specification
see........................"Maintenance Recommendations
and Recommended Service Products" booklet
Gearbox oil fill quantity
see........................Type plate, "Technical Data" or
"Maintenance Recommendations and Recommended Service Products" booklet.
Danger of damage! Ensure that the thread for the oil drain plug in the gearbox and Intarder housing is absolutely clean!
Fit new sealing rings on the oil drain plugs
2
(gearbox drainage point
3
drainage point
), screw them in and tighten them
Unscrew and remove oil filler plug
and Intarder housing
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
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
2
Oil drain plug Oil filler plug
and 3.................................60 Nm
1
..............................................60 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
9
breather
on the top of the gearbox
Note: Do not use high-pressure cleaners to clean
the breather.
WA 74 (3rd) 2.31 - 3
EATON FSO 8309 MANUAL GEARBOX
EATON FSO 8309 MANUAL GEARBOX
1
2
2
9-speed manual gearbox CHECKING THE OIL LEVEL (with vehicle parked on
a flat, level surface and cold gearbox oil <40 °C)
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.
Screw in and tighten the oil filler plug
Tightening torque
1
Oil filler plug
......................................20 – 27 Nm
CHANGING THE OIL (with the gearbox at operating temperature)
Draining the oil
2
Unscrew oil drain plug
Clean the oil drain plug's oil screen
and drain all the used oil
2
Filling with oil Gearbox oil specification
see........................"Maintenance Recommendations
and Recommended Service Products“ booklet
Gearbox oil fill quantity
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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