Operating Instructions

MAN Industrial Diesel Engines

D2876 LUE601/602/603/604/605/606

51.99493-8533 “Translation of the original operating instructions”

 Information and Copyright

Subject to technical alterations in the interests of further development.

Reprinting, copying or translating of these instructions, even in part, is forbidden without written permission
from MAN. All legal copyrights remain the exclusive property of MAN.

© 2011
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1930
E-Mail: engines.components@de.man-mn.com
Internet: www.man-engines.com

Editorial: EMDGG, Technical status: 08.2007

51.99493-8533

2
 Contents

Page

Information and Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
First commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
V‐belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Temporary decommissioning of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3
 Preface

Dear Customer,
these Operating Instructions are intended to familiarize you with your new MAN Diesel engine and how it
operates.
This manual is supplemented by the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”
and the ”Service record”.

Note:
All three publications belong to the engine and must always be kept ready to hand near the en­
gine in the engine room.
Comply in full with instructions relating to operation, prevention of accidents and environmental
protection.

MAN Diesel engines are developed and manufactured in line with the latest state of the art. However,
trouble‐free operation and high performance can only be achieved if the specified maintenance intervals
are observed and only approved fuels, lubricants and coolants are used.

Note:
Only use fuels, lubricants etc. in accordance with MAN's regulations.
Otherwise the manufacturer's liability for defects will not apply!
For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN
Diesel Engines”.
You can find the approved products in the internet under:
https://mmrepro.mn.man.de/bstwebapp/BSTServlet

It is imperative and in your own interest to entrust your MAN Local Service Centre with the removal of any
disturbances and with the performance of checking, setting, and repair work.

Best regards
MAN Truck & Bus AG
Nuremberg Plant

4
 Instructions

Important instructions which concern technical safety and protection of persons are emphasised as shown
below.

Danger:
This refers to working and operating procedures which must be complied with in order to rule out
the risk to persons.

Caution:
This refers to working and operating procedures which must be complied with in order to prevent
damage to or destruction of material.

Note:
Explanations useful for understanding the working or operating procedure to be performed.

5
 Nameplates

In all your correspondence please always quote engine model, serial number and job number (Order
number).
For this reason it is advisable to read off the data from the engine type plates before putting the engine into
operation and to enter them in the appropriate spaces.
The engine type plates are on the crankcase.

Model .................................................................

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

installed on .................................................................

Engine serial number .................................................................

Order number .................................................................

MAN Nutzfahrzeuge Aktiengesellschaft

Typ
Motor-Nr. / Engine No.
NI/II

MAN Nutzfahrzeuge Aktiengesellschaft

Aktiengesellsc
Werk Nürnberg Germany
:

Bauj. Year Typ Model Motor−Nr. Serial No

Werk−Nr. Job No Leistung kW Rating kW Drehz. 1/min Speed rpm

Temp.°C Leistg. PS Rating BHP Aufstellhohe m uNN Altitude m

:
:

−0219

6
 Safety regulations

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

1. Regulations designed to prevent accidents with injury to persons

During commissioning, starting and operation

D Before putting the engine into operation for the first time, read the operating instructions
carefully and familiarize yourself with the “critical” points. If you are unsure, ask your
MAN representative.

D For reasons of safety we recommend you attach a notice to the door of the engine
room prohibiting the access of unauthorized persons and that you draw the attention of
the operating personal to the fact that they are responsible for the safety of persons
who enter the engine room.

D The engine must be started and operated only by authorized personnel.

Ensure that the engine cannot be started by unauthorized persons.
D When the engine is running, do not get too close to the rotating parts. Wear close‐fitting
clothing.

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

D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel
ËË
engines which are to be operated in enclosed spaces. Ensure that there is adequate
ventilation and air extraction.
D Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

7
 Safety regulations

During maintenance and care

D Always carry out maintenance work when the engine is switched off.
If the engine has to be maintained while it is running, e.g. changing the elements of
change‐over filters, remember that there is a risk of scalding. Do not get too close to ro­
tating parts.

D Change the oil when the engines is warm from operation.

Caution:

ËË
There is a risk of burns and scalding. Do not touch oil drain plugs or oil filters with bare

ËË
hands.

D Take into account the amount of oil in the sump. Use a vessel of sufficient size to en­
sure that the oil will not overflow.
D Open the coolant circuit only when the engine has cooled down.
If opening while the engine is still warm is unavoidable, comply with the instructions in
the chapter entitled “Maintenance and Care”.

ËË
D Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any
additional hydraulic oil circuit) during the operation.
The fluids which flow out can cause injury.

D Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be
filled only when the engine is switched off.

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

D Keep service products (anti‐freeze) only in containers which can not be confused with
drinks containers.

D Comply with the manufacturer's instructions when handling batteries.

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

8
 Safety regulations

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

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

9
 Safety regulations

3. Regulations designed to prevent pollution

Engine oil and filter elements / cartridges, fuel / fuel filter

D Take old oil only to an old oil collection point.
D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
Caution:
The drinking water supply could be contaminated.
D Filter elements are classed as dangerous waste and must be treated as such.

Coolant
D Treat undiluted anti‐corrosion agent and / or anti‐freeze as dangerous waste.
D When disposing of spent coolant comply with the regulations of the relevant local authorities.

10
 Safety regulations

4. Notes on safety in handling used engine oil ∗

Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, ir­
ritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous sub­
stances which have caused skin cancer in animal experiments. If the basic rules of hygiene and health and
safety at work are observed, health risks are not to the expected as a result of handling used engine oil.
Health precautions:
D Avoid prolonged or repeated skin contact with used engine oil.
D Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
D Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water. A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
D After washing apply a fatty skin cream to the skin.
D Change oil‐soaked clothing and shoes.
D Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly
- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are
punishable.
Collect and dispose of used engine oil carefully. For information on collection points please contact the
seller, the supplier or the local authorities.
∗ Adapted from “Notes on handling used engine oil”.

11
 Commissioning and operation

Engine views
1 2 3 4

12

11 10

12
 Commissioning and operation

(1) Turbocharger

(2) Solenoid valve for flame‐starter

(3) Flame‐starter sheathed‐element glow plug

(4) Crankcase breather

(5) TDC mark

(6) Water pump

(7) Oil filter

(8) Injection pump

(9) Engine / EDC harness

(10) Oil drain plugs

(11) Dipstick

(12) Air compressor

13
 Commissioning and operation

First commissioning
At the time of initial commissioning of a new or overhauled engine make sure to have observed the “Tech­
nical Information for the installation of MAN Diesel engines”.
It is recommended that new or overhauled engines should not be operated at a load higher than about 75%
maximum load during the first few hours of operation. Initial run‐in should be at varying speeds After this
initial run‐in, the engine should be brought up to full output gradually.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the
manufacturer's warranty will become null and void.

Filling with fuel

Caution:
Fill the tank only when the engine is switched off. Pay attention to cleanliness. Do not spill fuel.
Use only approved fuels, see brochure “Fuels, lubricants etc.”.

Filling‐in of coolant
Fill the cooling system of the engine with a mixture of drinkable tap water and anti‐freeze agent on the
ethylene glycole basis or anti‐corrosion agent.
See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.
D Observe / adhere to vehicle manufacturer's filling specifications
D Slowly pour in coolant (max. 10 ltr./min)

Filling engine oil

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

The engines are as a rule supplied without oil.

Pour oil into engine via filler neck, see page 19.
For the quantity required see “Technical Data”.

14
 Commissioning and operation

Commissioning
Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if neces­
sary.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the
manufacturer's warranty will become null and void.

Checking oil level

Check the oil level when the engine is horizontal,

but only if at least 20 minutes have passed since Oil

?
the machine was switched off.
D Pull out dipstick
D wipe it with a clean, lintfree cloth
D and push it in again up to the stop
D Pull out dipstick again
The oil level should be between the two notches in MAX
the dipstick and must never fall below the lower
MIN
notch. Top up any missing oil.

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

Ensure outmost cleanliness when handling fuels,

lubricants and coolants.
The engine is equipped with a maximum/minimum oil level monitoring system.
During the starting procedure the level probe is checked by the vehicle control system. If a fault is found
the system will refuse to start the engine in order to prevent damage. The oil level is not monitored when
the engine is running.

Caution:
Add engine oil only when the engine is not running!

15
 Commissioning and operation

Starting

Danger:
Before starting make sure that no‐one is in the engine's danger area.

Caution:
When starting do not use any additional starting aids (e.g. injection with starting pilot).

Multi‐engine systems start via an automatic start‐stop system.

This must fulfil the following functions:
D Switch on EDC
D Oil level monitoring
D Triggering of flame start system
D Starting procedure initiated after preglowing (start assistance) and interrupted after engine starts at ap­
prox. 300-400 rpm
D Should the engine not start - starting time restricted to 10-15 seconds
D Repeat start attempt 3-4 with 15-20 second pause in between
D Fault indication upon unsuccessful start
Avoid running the cold engine for any length of time since in any internal combustion engine this is liable to
cause increased wear due to corrosion. Prolonged idling is harmful to the environment.

16
 Commissioning and operation

Operation monitoring system

Caution:
Do not overload the engine. Do not exceed the maximum permissible tilt of the engine. If faults
occur, find their cause immediately and have them eliminated in order to prevent more serious
damage!

Monitor the oil pressure of the engine lubrication and coolant agent temperature during operations.
If the monitoring equipment displays a drop in the pressure of lubrication oil or excess coolant temperature
then the engine must be turned off immediately

Shutting down
Set engine to idle speed.
After engine has been under a heavy load let it run idle for approx. 5 minutes.
Turn off engine via EDC.

Danger:
Ensure that the engine cannot be started by unauthorized persons.

17
 Maintenance and care

Lubrication system
Ensure utmost cleanliness when handling fuels, lubricants and coolants.

Caution:
Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the
manufacturer's warranty will become null and void.

Refilling with oil

Caution:
Used oil is dangerous waste.
Observe safety regulations to prevent
damage to the environment.

With the engine at operating temperature, remove

the oil drain plugs on the oil sump and the oil filter
bowl and allow the old oil to drain off completely.
Use a vessel of sufficient size to ensure that the oil
does not overflow.

Danger:
The oil is hot - risk of scalding. Do not
touch the oil drain plug with bare fingers.
Oil is an environmental hazard. Handle it
with care!

Refit the oil drain plugs with new gaskets.

18
 Maintenance and care

Refilling with oil

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

Refill with fresh engine oil at the oil filler neck

(arrow).
After filling start the engine and let it run for a few
minutes at low speed.

Caution:
If no oil pressure builds up after approx.
10 seconds switch off the engine immedi­ Oil

?
ately.

Check oil pressure and check that there is no oil

leakage.
Then shut down the engine. After about 20 min­
utes, check the oil level.
D Pull out dipstick
D wipe it with a clean, lintfree cloth MAX
D and push it in again up to the stop
D Pull out dipstick again MIN

The oil level should be between the two notches in the dipstick and must never fall below the lower notch.
Top up any missing oil.

Note:
Change the oil filter element every time the engine oil is changed.

If the minimum level is not reached the vehicle control system refuses to carry out the start. Top up any
missing oil.
Before starting again wait for 2-3 minutes until the oil has settled in the oil pan.
If there is too much oil in the engine the vehicle control system will likewise refuse to carry out the start.
Drain out oil until the maximum level is reached and then start again.

19
 Maintenance and care

Changing oil filter

Caution:
Used oil and oil filters are classed as dan­
gerous waste.
Observe safety regulations to prevent
damage to the environment.

D Allow the filter content to run off along drain

plug. Use a vessel of sufficient size to ensure
that the oil does not overflow

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

D After relesing the clamping bolt remove filter

bowl
D Refit the oil drain plug with a new seal.
D Renew filter cartridge. Thoroughly clean all
other parts in cleaning fluid (do not allow clean­
ing fluid to enter the oil circuit).
D Use new gasket for reassembly of filter bowl

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

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

20
 Maintenance and care

Fuel system

Fuel
If Diesel fuel which contains moisture is used the injection system and the cylinder liners / pistons will be
damaged. This can be prevented to same extent by filling the tank as soon as the engine is switched off
while the fuel tank is still warm (formation of condensation is prevented). Drain moisture from storage tanks
regularly. It is also advisable to use a water separator instead of the pre‐filter. Do not use any additives to
improve flow properties in winter.

Injection pump
No alterations must be made to the injection pump. If the lead seal is damaged the warranty on the engine
will become null and avoid.

Faults
We urgently recommend that you have faults in the injection pump rectified only in an authorised specialist
workshop.

Fuel pre‐filter with water separator

Draining water:
D Open drain screw (1) and let off water.
D Close drain screw (1) again

Changing filter element

Only when the engine is swiched off.
D Remove inspection glass (2) and filter element
(3)
3
D Wet seal on new filter with fuel
D Screw on filter (3) and inspection glass (2) by
hand
D After this, bleed the fuel system
D Check filter for leaks

Caution:
Used fuel filters are classed as danger­ 2
ous waste and must be disposed of ac­
cordingly.
1

21
 Maintenance and care

Cleaning fuel pre‐cleaner

Strip the fuel pre‐cleaner:
D Remove filter housing (1)
D Wash out filter housing (1) and gauze filter (2)
in clean Diesel fuel and blow them out with
compressed air
D Reassemble using new seal
D Screw on filter housing and tighten it to
10-12 Nm
D Actuate tappet of hand primer until overflow
valve of injection pump is heard to open 1 2
D Screw in and tighten plunger on hand pump
D Start engine
D Check fuel pre‐cleaner for leaks

Changing fuel filter

Only when the engine is swiched off.
D Remove filter cartridge using tape wrench.
D Wet seal on new filter with fuel
D Screw on filter by hand
D After this, bleed the fuel system
D Check filter for leaks

Caution:
Used fuel filters are classed as danger­
ous waste and must be disposed of ac­
cordingly.

22
 Maintenance and care

Bleeding the fuel system

Note:
To bleed the fuel system switch on the
“ignition” so that the EHAB will be open.

An arrow on the filter head indicates the direction

of fuel flow.
D Unscrew bleed screw of first filter in direction of
flow by one or two turns
D Actuate tappet of hand primer until fuel
emerges without bubbles
D Close bleed screw
D Repeat this procedure at the second bleed
screw
D Check filter for leaks

23
 Maintenance and care

Cooling system

Danger:
Draining hot coolant involves a risk of scalding.

Draining the cooling system

Drain coolant when the engine is cold as follows:

Caution:
Drain coolant into a suitable container and dispose of it in accordance with regulations.

D Briefly open cap on filler neck of the expansion

tank for pressure compensation
D Unscrew and remove drain plugs, then remove
cap
D Drain coolant into a container of adequate size
D Refit screw plugs
D Fill / bleed the cooling system
D Follow instructions of vehicle manufacturer

24
 Maintenance and care

Filling / bleeding the coolant system

(Only when the engine is swiched off)
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze agent on the
ethylene glycole basis or anti‐corrosion agent.
See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines”.
Coolant must be poured in according to the vehicle manufacturer's filling specifications. Do not
pour any cold coolant into an engine which is still warm. Ensure that the ratio of water to anti‐
freeze is correct.
D Slowly pour in coolant (max. 10 ltr. / min)
D Run the engine briefly and then check coolant level once more

Danger:
If, in exceptional cases, the coolant level on warm engines has to be checked or the cooling circuit
opened, observe the vehicle manufacturer's safety regulations.

Improper mixing of anti‐freeze and corrosion inhibitors may lead to lime and corrosion deposits in the en­
gine cooling system which can jeopadize cooling efficiency.
In such cases it is necessary to clean the cooling system at suitable intervals.

25
 Maintenance and care

Air filter
An air filter is installed in the vehicle to purify the air for combustion.
The intervals at which the air cleaner requires servicing depend on the specific operating conditions en­
countered. Clogged air filters may cause black smoke and reduce power.
The air filter is fitted with a contamination gauge. This shows the condition of the air filter by changing co­
lour and thus indicates when the filter should be maintained.
A check should be made from time to time to see that the fastening elements securing the air cleaner to the
intake manifold seal the connection tightly. Any ingress of unfiltered air is liable to cause a high rate of cyl­
inder and piston wear.

26
 Maintenance and care

V‐belts

Checking condition
D Check V‐belts for cracks, oil, overheating and
wear
D Change damaged V‐belts

Checking tension
Use V‐belt tension tester to check V‐belt tension.
D Lower indicator arm (1) into the scale
D Apply tester to belt at a point midway between
two pulleys so that edge of contact surface (2)
is flush with the V‐belt
D Slowly depress pad (3) until the spring can be
heard to disengage. This will cause the indica­
tor to move upwards 1
If pressure is maintained after the spring has dis­
engaged a false reading will be obtained!

Reading of tension
D Read of the tensioning force of the belt at the
point where the top surface of the indicator arm
(1) intersects with the scale
D Before taking readings make ensure that the
indicator arm remains in its position 2
If the value measured deviates from the setting
value specified, the V‐belt tension must be cor­
rected.

Tension force in cold condition according to kg scale on tester

Drive belt width 2-3VX
New Installation Installation 90-100
After 10 min. running time 70-80
Minimum tension force 50
Retensioning value after minimum tension force is reached 60

27
 Maintenance and care

Tensioning and changing V‐belt

D Loosen securing bolts (1)

D Remove lock‐nut (2)
D Adjust nut (3) until V‐belt have correct tension
D Retighten lock‐nut and fixing bolts 1
To replace the V‐belts loosen lock‐nut and swing
alternator inwards.

Alternator
The alternator is maintenance‐free.
Nevertheless, it must be protected against dust and, above all, against moisture.
In order to avoid damage to the alternator, observe the following instructions:

While the engine is running

D Do not de‐energize the main battery switch!
D Do not disconnect the battery or pole terminals or the cables!
D Do not operate the alternator without battery connection!

28
 Maintenance and care

Temporary decommissioning of engines

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

Turbocharger
At every engine oil change check the oil pipes for leaks and constrictions.
Furthermore, a regular check should be kept on charge air and exhaust gas pipes.
Any leakages should be attended to at once because they are liable to cause overheating of the engine.

Starter motor
Check that the electric cables are properly fastened and that contacts and plug connections are secure.

Note:
Always disconnect the battery earth cable before starting work on the electrical system. Connect
up the earth cable last, as there is otherwise a risk of short‐circuits.

29
 Technical data

Model D 2876 LUE 601 / 602 / 603 / 604 / 605 / 606

Design in‐line, underfloor
Cycle 4‐stroke Diesel with turbocharger and intercooler
Combustion system Direct injection
Turbocharging Turbocharger with intercooler
Number of cylinders 6
Bore 128 mm
Stroke 166 mm
Swept volume 12 816 cm3
Compression ratio 16,75 : 1
Rating see engine nameplate
Firing order 1-5-3-6-2-4
Valve clearance (cold engine)
Intake 0.50 mm
Exhaust 0.60 mm
Valve timing
Intake opens 23 ° before TDC
Intake closes 12° after BDC
Exhaust opens 60° before BDC
Exhaust closes 30° after TDC
Fuel system
Injection pump Bosch control slide injection pump RP 39
Governor Electronic Diesel Control (EDC) - Model MS 5.5
Start of delivery 2 °+1 ° after TDC
Injectors seven‐hole nozzles
Opening pressure of injector:
New nozzle holder: 320+8 bar
Used nozzle holder: 320+8 bar

30
 Technical data

Engine lubrication Force feed

Oil capacity in oil sump (litres) min. max.
24 l 30 l
Oil change quantity (with filter) 33 l
Oil pressure during operation (depending on oil must be monitored by oil pressure monitors / gau­
temperature, oil viscosity class and engine ges
rpm)
Oil filter Full flow filter with paper cartridges
Engine cooling system Liquid cooling
Coolant temperature 80-90°C, temporarily 95°C allowed
Electrical equipment
Starter 24 V; 5.4 kW

31
 Maintenance chart

Engine model: Order date:

Engine number:
Operating hours: Signature:

Position Maintenance jobs

j A Clean water separator / pre‐filter
j A1 Change fuel filter, clean water separator, clean pre‐filter
j B Check injection nozzles - renew if necessary, compression pressure, renew turbocharger
S Change oil and oil filter, check that components are tight
j C S Check V‐belts for damage, tighten up or change
S Check connection elements (bolts, clamps etc.) and tighten if necessary
j D Tighten cylinder head bolts
j E Check valve clearance and adjust if necessary
j F Renew axial face seal and bearing on coolant pump
S Check cable connectors, renew if necessary
j G S Check funktion for engine monitoring system
S Check starter and generator, renew if necessary
j H Clean air filter and change filter cartridge, set back display
j H1 Change air filter / filter cartridge
j J Check concentration of coolant, correction if necessary
Realisation at the latest all 4 years, operating hours independent
j J1 S Renew coolant
S Renew valve caps at the expansion tank
S Check oil level
S Check coolant level
S Check maintenance display on air filter
j K S Check water separator
S Check regarding pending EDC errors
S Visual check for exterior damage, stone impact, leakages
j M Check coupling Front‐PTO, clean it and renew wear parts
j N Tighten the mounting nut on the compression flange injector 90_

Caution:
Use engine oils to MAN works standard M 3275 or M 3277 only!
D 2876 LUE 605-606 ! M 3275 oder M 3277
D 2876 LUE 601-604 ! M 3277

32
 Maintenance chart

Operating Maintenance plan based on operating hours for MAN engine

hours
Daily K
20 A C N
400 A C D E H J
800 A C E H J
1200 A1 C H J
1600 A C E H J
2000 A C H J
2400 A1 C E H1 J
2800 A C H J
3200 A C E H J
3600 A1 C H J
4000 A C E H J
4400 A C H J
4800 A1 C E H1 J M
5200 A C H J
5600 A C E H J
6000 A1 C H J
6400 A B C E F H J
6800 A C H J
7200 A1 C E H1 J
7600 A C H J
8000 A C E H J
8400 A1 C H J
8800 A C E H J
9200 A C H J
9600 A1 C E G H1 J1 M
10000 A C H J
10400 A C E H J
10800 A1 C H J
11200 A C E H J
11600 A C H J
12000 A1 C E H1 J
12400 A C H J
12800 A B C E F H J
13200 A1 C H J
13600 A C E H J
14000 A C H J
14400 A1 C E H1 J M
14800 A C H J
15200 A C E H J
15600 A1 C H J
16000 A C E H J

33
 Troubleshooting table

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

34
 Troubleshooting table

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

35
 Index

A M
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - 28 Maintenance and care . . . . . . . . . . . . . . . . . 18 - 29
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
N
B Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . 23
O
C Operation monitoring system . . . . . . . . . . . . . . . . 17
Changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 15 P
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Pre-cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Commissioning and operation . . . . . . . . . . . 12 - 17
R
Cooling system . . . . . . . . . . . . . . . . . . . . . . . 24 - 27
Refilling with oil . . . . . . . . . . . . . . . . . . . . . . . . 18, 19
D
S
Draining the cooling system . . . . . . . . . . . . . . . . . 24
Safety regulations . . . . . . . . . . . . . . . . . . . . . . 7 - 11
E Handling used engine oil . . . . . . . . . . . . . . . . . . 11
Engine views . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13 Preventing accidents with injury to persons . . . 7
Preventing damage to engine
F and premature wear . . . . . . . . . . . . . . . . . . . . . . . 9
Filling / bleeding the coolant system . . . . . . . . . . 25 Preventing environmental damage . . . . . . . . . 10
Filling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling with fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Filling-in of coolant . . . . . . . . . . . . . . . . . . . . . . . . 14 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First commissioning . . . . . . . . . . . . . . . . . . . . . . . 14
T
Fuel filter, Changing fuel filter . . . . . . . . . . . . . . . 22
Technical data . . . . . . . . . . . . . . . . . . . . . . . . 30 - 31
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - 24
Temporary decommissioning of engines . . . . . . 29
I Troubleshooting table . . . . . . . . . . . . . . . . . . 34 - 35
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

L V
Lubrication system . . . . . . . . . . . . . . . . . . . . 18 - 21 V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 28

36
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nürnberg
Germany

A member of the MAN Group

Printed in Germany 51.99493-8533