Man D 2876 LE 101 Operating Instructions Manual
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Man D 2876 LE 101 Operating Instructions Manual

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Summary of Contents for Man D 2876 LE 101

  • Page 3 Operating Instructions − MAN Industrial Diesel Engines...
  • Page 5 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.
  • Page 6 Flat seals / gaskets can be fitted properly only if the following points are ob- served: D Use only genuine MAN seals / gaskets D The sealing faces must be undamaged and clean D Do not use any sealing agent or adhesive − as an aid to fitting the seals a little grease...

  • Page 7: Table Of Contents

    Contents Page Declaration ............. . . Nameplates .

  • Page 8: Declaration

    In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of Directive 89/392/EEC, version 93/44/EEC MAN Nutzfahrzeuge Aktiengesellschaft, hereby declares that the engine described below is destined for installation in a machine as defined in the EC directive on machines.

  • Page 9: Nameplates

    ............MAN Nutzfahrzeuge Aktiengesellschaft Motor-Nr.

  • Page 10: Safety Regulations

    Ë Ë D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction. D Keep vicinity of engine, ladders and stairways free of oil and grease.
  • Page 11 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 scald- ing.
  • Page 12 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 result- ing from the installation of other parts which are supposedly “just as good”.
  • Page 13 Safety regulations 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.

  • Page 14: Commissioning And Operation

    At the time of initial commissioning of a new or overhauled engine make sure to have ob- served the “Technical 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.

  • Page 15: Commissioning

    Commissioning and operation Commissioning Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if necessary. Note: 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...

  • Page 16: Starting

    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). D Ensure that no load is on the engine before starting it, eg switch off load, disengage clutch, put gearbox into neutral etc.

  • Page 17: Operation Monitoring System

    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.

  • Page 18: Maintenance And Care

    Maintenance and care Lubrication system Ensure utmost cleanliness when handling fuels, lubricants and coolants. Note: Use only approved fuels, lubricants etc. (see brochure “Fuels, lubricants etc.”). Otherwise the manufacturer’s warranty will become null and void. Refilling with oil Danger: The oil is hot- risk of scalding. Do not touch the oil drain plug with bare fingers.
  • Page 19 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 À.
  • Page 20 Maintenance and care Changing oil filter Caution: Used oil and oil filters are classed as dangerous waste. Observe safety regulations to prevent dam- age to the environment. Open oil drain plug on oil filter can and use container to catch oil that may emerge.
  • Page 21 Maintenance and care Changing oil filter Caution: Used oil and oil filters are classed as dangerous waste. Observe safety regulations to prevent dam- age to the environment. Release oil filter cap with special tool until sealing ring  is visible, wait approx. 2 minutes until the oil has drained from the filter bowl.

  • Page 22: Fuel System

    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 con- densation is prevented).
  • Page 23 Maintenance and care Fuel filter Parallel fuel filter Draining moisture: Unscrew drain plugs at every oil change until moisture has been discharged and clean fuel flows out. Changing fuel filter Only when the engine is swiched off. D Loosen filter cartridge by means of tape wrench, unscrew it by hand and take it D Moisten the seals on the new filter car- tridge with fuel...
  • Page 24 Maintenance and care Fuel service center KSC Cleaning fuel pre-cleaner D Screw off housing cap À D Remove and clean cap and strainer el- ement  D Replace sealing ring Á D Screw in strainer element and cap and tighten down to 25 Nm D Bleeding the fuel system D Check filter for leaks Bleeding the fuel system...

  • Page 25: Cooling System

    Maintenance and care Cooling system Danger: Draining hot coolant involves a risk of scalding. Draining the cooling system Caution: Drain coolant into a suitable container and dispose of it in accordance with re- gulations. Drain coolant as follows when cooling sys- tem has cooled down: D Open cap on filler neck of expansion tank for pressure compensation and...
  • Page 26 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 specifi- cations.

  • Page 27: V-Belts

    Maintenance and care V-belts Checking condition If, in the case of a multiple belt drive , wear or differing tensions are found, al- ways replace the complete set of belts. D Check V-belts for cracks, oil, overheat- ing and wear D Change damaged V-belts Checking tension Use V-belt tension tester to check V-belt...
  • Page 28 Maintenance and care Tension force in cold condition according to kg scale on tester Drive belt width 10.0 13.0 2-AVX13 New installation Installation 45−50 50−55 100−110 After 10 min. running time 35−40 40−45 80−90 When servicing after long running time Minimum tension force Retensioning value after minimum tension force is re- ached...
  • Page 29 Maintenance and care Fan − Tension pulley D Remove fixing bolts À D Remove lock-nut Á D Adjust nut  until V-belts have correct tensions D Retighten lock-nut and fixing bolts To change the V-belts, remove the fan, turn back the setting nut  and swivel the tension pulley inwards.
  • Page 30 Maintenance and care Ribbed V-belts Checking condition D Check ribbed V-belts (poly-V-belts) for cracks, fouling by oil, overheating and wear D Replace damaged ribbed V-belts Checking tension D Attach setting gauge À over bolt heads of spring mounting. The pretension on the automatic belt tensioner is correct when the setting gauge can be at- tached over the bolt heads...

  • Page 31: Turbocharger

    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...

  • Page 32: Technical Data

    Technical data Model D 2876 LE 101 / 103 / 104 / 105 Design in-line vertical Cycle 4-stroke Diesel with turbocharger and in- tercooler Combustion system Direct injection Turbocharging Turbocharger with intercooler Number of cylinders Bore 128 mm Stroke 166 mm...
  • Page 33 Technical data Engine lubrication Force feed Oil capacity in oil sump (litres) min. max. deep 24 l 30 l shallow 24 l 30 l with yoke 33 l 39 l Oil change quantity (with filter) deep / shallow 33 l with yoke 42 l Oil pressure during operation (depend-...

  • Page 34: Maintenance Chart

    Maintenance chart ALWAYS COMPLY WITH SAFETY REGULATIONS ! Maintenance cycles Maintenance jobs in hours of operation Daily 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 8000 8400 8800 9200 9600 10000 10400 10800 11200...
  • Page 35 D Visual check for exterior damage, stone impact, leakages Every 4 years regardless of operating hours D Renew coolant D Replace radiator cap (filler valve, service valve) The prescribed maintenance intervals presuppose the use of engine oil as per MAN works norms M3277!

  • Page 36: Troubleshooting Chart

    Troubleshooting chart Note: The troubleshooting chart applies to engines with EDC MS5/5.32. For engines with EDC MS 6.1, not all points are applicable (EDC-specific). EDC self-diagnosis or flash code output Starter turns over engine only slowly or not at all Starter turns, engine does not start, engine does not start / difficult to start when cold Engine stalls (dies) during operation, no longer starts (starter turns), engine does not start / starts with difficulty when hot...
  • Page 37 Troubleshooting chart EDC self-diagnosis or flash code output Starter turns over engine only slowly or not at all Starter turns, engine does not start, engine does not start / difficult to start when cold Engine stalls (dies) during operation, no longer starts (starter turns), engine does not start / starts with difficulty when hot Sudden, temporary engine shut-down, engine does not reach full revs Engine only runs at idle speed, no throttle response...
  • Page 38 Line defective: Pin 23 or 41 o o o EDC control unit faulty (internal fault) o x x Incorrect EDC control unit (check MAN part number) Incorrect intermediate speed switched on EOL programming terminated / voltage interrupt Afterrunning not completed (e.g. shutdown via EMERGENCY STOP)
  • Page 39 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 40: Index

    Index Bleeding the fuel system ....23, 24 Maintenance and care ....18–29 Maintenance chart .

This manual is also suitable for:

D 2876 le 103D 2876 le 104D 2876 le 105

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