0998 0,12 ff
Grinding valves ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922 /923, 15
906.910 /911 /920 /921 /922 /923
ENGINE 904.908 in MODEL 668,670
ENGINE 906.940/941 in MODEL 957
Removing, installing camshaft ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 18
/911 /920/921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
ENGINE 906.940/941 in MODEL 957
Removing, installing MR/PLD control unit ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 24
/911/920 /921 /922 /923
Removing and installing MR/PLD Injection lines ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 27
/911 /920 /921 /922 /923
ENGINE 904.908 in MODEL 668,670
ENGINE 906.940 /941 in MODEL957
Removing and installing nozzle holder combination ENGINE 904.905/906/907/921 ##upto40487 31
ENGINE 904.908 # # up to 40487 in MODEL 668, 670
Removing and installing nozzle holder combination ENGINE 904.905 /906 /907 /921 # # as of 40488 34
ENGINE 904.908 # # as of 40488,
904.923
in MODEL 668, 670
ENGINE 904.909/910/911 /922,906.910/911 /920/921 /922
/923 /940 /941
Removing and installing MR/PLD unit pump ENGINE 904.905/906/907 /908/909/910/911 /921 1922, 37
906.910 /911 /920 /921 1922 /923 /940 /941
Removing, adjusting and installing crankshaft angle position ENGINE 904.905 /906 /907 /909/910/911 /921 /922,906.910 41
sensor bracket /911 /920/921 1922 /923/940/941
Testing low pressure fuel circuit ENGINE 904.905 /906 /907 /921 # # up to 040487 43
Testing low pressure fuel circuit ENGINE 904.905 /906 /907 /921 # # as of 040488 58
ENGINE 904.909/910/911 /922,906.910/911 /920/921 /922
/923 /940 /941
Inspecting turbocharger ENGINE 904.905/906/907/909/910/911 /921 /922,906.910 67
/911 /920 /921 /922 /923 /940/941
Removing and installing turbocharger ENGINE 904.905/906/907/909/910/911 /921 /922, 906.910 70
/911 /920 /921 1922 /923 /940/941
Removing, installing boost air pipe ENGINE 904.905/906/907/921 75
Removing, installing boost air pipe ENGINE 904.909 /910 /911 /922,906.910/911 /920 /921 /922 76
/923/940/941
Removing, installing boost air pipe F N G IN F 904.909/910/911 /977. 906 910 /911 /970/971 /977 77
/923
From intercooler to boost air manifold
Removing and installing boost air manifold ENGINE 904.905/906/907/921 79
Removing, installing boost air manifold E N G IN F 904.909/910/911 /922, 9 06 .9 1 0 /911 /920/921 /922 81
/923 /940 /941
Removing, installing boost pressure, boost air temperature ENGINE 904.909/910/922/911,906.910/911 /920/921 /922 83
sensor /923
Testing intercooler and boost air hoses for leaks ENGINE 904.909 /910/911 /922,906.910/911 /920/921 /922 84
/923
Removing, installing poly V-belt ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922,906.910 86
/911 /920 /921 /922/923
Removing, installing poly V-helt tensioning device F N G IN F 904 905 /906 /907 /909 /910 /911 /921 /922. 906.910 88
/911 /920 /921 1922 /923
ENGINE 904.908 /923 in MODEL 668,670
ENGINE 906.940/941 in MODEL957
Removing, installing compressor ENGINE 904.905 /906 /907 /909 /910 /911 /921 /922, 906.910 89
/911 /920 /921 /922 /923
2
GF01.00-W-2000A Technical data engine complete 17.4.96
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
O
Li.
GF01.00-W-1000-01B Technical data engine Engine 904.906/908
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
4
Engine model designation 904.906/908
Engine type OM 904LA 11/1
Engine power (P) kW/HP 100(136)
rpm 2300
Engine torque (M) max. Nm 520
rpm 1200-1500
Rated speed rpm 2300
Bore mm 102
Stro ke mm 130
Total displacement cm3 4250
Compression ratio e 17,4
Firing order 1-3-4-2
Number and arrangement of cylinders 4 inline
Valves Inlet 2
Exhaust 1
Working method 4-stroke diesel with direct injection
Combustion method Exhaust turbocharger and intercooler
Injection method Single unit pump with pump-line-nozzle system (PLD)
Timing Electronic engine management with solenoid valve-controlled fuel
injection
Specific fuel consumption (b) g/kWh (see diagram)
P Engine o u tp u t
M Engine torque
n Rated speed
b Specific fuel consumption
W01.00-0004-12
Additional Information
Stroke mm 130
Total displacement cm3 4250
Compression ratio e 17,4
Firing order 1-3-4-2
Number and arrangement of cylinders 4 inline
Valves Inlet 2
Exhaust 1
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
Engine model designation 904.909
Engine type OM 904 LA 11/2
Engine power (P) kW/HP 90/122
rpm 2300
Engine torque (M) max. Nm 470
rpm 1200-1500
Rated speed rpm 2300/2500
Bore mm 102
Stroke mm 130
Total displacement cm3 4250
Compression ratio e 18,0
Firing order 1-3-4-2
Number and arrangement of cylinders 4 inline
Valves Inlet 2
Exhaust 1
Working method 4-stroke diesel with direct injection
Combustion method Exhaust turbocharger and intercooler
Injection method Single unit pump with pump-line-nozzle system (PLD)
Timing Electronic engine manaqement with solenoid valve-controlled fuel
injection
Specific fuel consumption (b) g/kWh (see diagram)
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
Engine model designation 904.921/922/923
Engine type OM 904 LA II/8
Engine power (P) kW/HP 112/152
rpm 2300
Engine torque (M) max. Nm 580
rpm 1200-1300
Rated speed rpm 2300/2500
Bore mm 102
Stroke mm 130
Total displacement cm3 4250
Compression ratio e 18,0
Firing order 1-3-4-2
Number and arrangement of cylinders 4 inline
Valves Inlet 2
Exhaust 1
W o r k in g m eth o d 4-stroke diesel w ith d ire c t Injectio n
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
P Engine output
M Engine torque
n Rated speed
b Specific fuel consumption
Additional Information
Engine model designation 906.911/921/922
Engine type OM 906 LA II/3
Engine power (P) kW/HP 205/280
rpm 2300
Engine torque (M) max. Nm 1100
rpm 1260-1500
Rated speed rpm 2300/2500
Bore mm 102
Stroke mm 130
Total displacement cm3 6370
Compression ratio e 18.0
Firing order 1-4-2-5-3-6
Number and arrangement of cylinders 6 inline
Valves Inlet 2
Exhaust 1
W o r k in g m eth o d 4-stroke d iesel w ith direct in jectio n
Additional Information
X2.1 Connector
X2.2 Connector
X2.3 Connector
W01.00-1001-06
m m Removing, installing
/\ Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 13
poisoning and burns from swallowing Wearacid-resistantgloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
4 Take off cover (2) at cab -chassis connector IH Installation: cover of cab - chassis
(1) connector must be closed tight
HI 000 589 01 10 00
6 Unclip engine wiring harness (4) and place Do not damage engine wiring harness
down
Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
7 Tilt cab
Additional Information
12
8 Take engine wiring harness (4) out at the @ Do not damage engine wiring harness
fixture at the right-hand frame
lo n g itu d in a l m em b er a n d tie u p a t e n g in e
/2223-T
8g 0
0 0 0 @ @
2224-T
n n n n n n n n
Torxbitset
AS54.10-Z-0001-01A Explosion hazard from explosive gas. Flames, sparks, open light and Danger!
Danger of poisoning and acid burns when smoking prohibited, w ear acid
battery acid is swallowed. Danger of acid resistant gloves, clothing and goggles.
burns to skin and eyes from battery acid or Store battery acid only in suitable,
when handling damaged lead-acid appropriately marked containers.
batteries.
Possible dangers
Injury hazard
Explosion Hazard Battery acid contains sulfuric acid, which can cause severe burns
A highly explosive gas mixture is generated when lead-acid to skin and eyes. W hen handling damaged lead-acid batteries
batteries are charged (removing from accident vehicle) increased care is necessary due
to the sharp edges on the broken housing and direct contact with
Poisoning hazard the lead plates.
When battery acid is taken orally toxic symptoms can occur such
as headache, dizziness, stomach pain, paralysis of the respiratory Rules of behavior/protective measures
system, unconsciousness, vomiting, acid burns and cramps. - Charge lead-acid batteries only in well ventilated rooms.
Battery acid vapor can burn eyes. Inhalation can result in burns to Fire, sparks, open light and smoking prohibited.
mucous membranes and respiratory paths. - Do not lay tools or other conductive items on lead-acid
Lead in the body can damage blood, nerves and kidneys; batteries (danger of short circuiting).
moreover, lead compounds pose a hazard for the reproduction - Disconnect and remove lead-acid batteries for charging.
organs. - Always disconnect negative pole first; always connect positive
pole first.
- Switch on charger only after connecting to poles; switch off
before disconnecting.
Additional Information
P S 4.1 0 *0 2 7 0 -0 8
1 Fire, sparks, open light and smoking 3 Observe operating instructions 6 Keep away from children
prohibited 4 Danger o f acid burns 7 First aid
2 Explosion hazard 5 W ear eye protection
Additional Information
14
AH 54.10-P-0001 -01A Notes on battery All models
Do not store lead-acid batteries for extended periods of time Do not switch on battery chargers until they have been
in a place where they are exposed to direct sunlight. connected to the battery poles; switch them off before
Always store lead-acid batteries horizontally to prevent acid disconnecting.
from escaping; do not tilt them when they are being Only charge lead-acid batteries with direct current. For the
transported. charging current we recommend 10% of capacity for normal
Discharged or faulty lead-acid batteries can freeze up; charging and 50% of capacity for rapid charging.
t h e re fo re , en su re t h a t th e y a rc sto red a t te m p e ra tu re s a b o v e D u rin g rapid charging it must be Insured that the casing Of the
feezing level. lead-acid battery does not warm up excessively (< 55 C).
Do not place any tools or other electrically conductive objects Lead-acid batteries should be kept clean and dry as far as
on a lead-acid battery (risk of short-circuit!). possible.
Avoid mixing up positive and negative poles and avoid short- it is advisable to grease the poles lightly with battery pole
circuits. grease.
Before removing or installing a lead-acid battery, switch off all Lead-acid batteries should not be stored for extended periods
electrical consumers where possible, and switch off the engine, without being recharged.
so as to minimize the possibility of creating sparks. If a lead-acid battery is to remain in a vehicle which is not in
Always disconnect the negative pole first; always connect the use for an extended period, the negative terminal clamp
positive pole first. should be disconnected.
Bearbeitungsvermerk
Datum ; Ersteiier j Vermerk i Se/te
AS60.80-Z-0001-01A Injury hazard from pinching and crushing When tilting ensure that no one is Danger!
when cab is tilted present in the tilting area of the cab.
Always tilt cab to end position and
secure with safety brace.
Injury hazard
A damaged tilting mechanism or improper handling of the tilting
mechanism can lead to severe injuries when tilting the cab. When tilting cab:
- Protect tilting area and particularly tilting device against
Rules o f b e h a v io r/ p ro te c tiv o m ea su res u n a u th o riz e d access, e.g. by b lo ckin g o ff o r w it h h u m a n
Before tilting cab: guard.
- Shut off engine. - Attach safety cable before tilting when so specified in the
- Apply parking brake. vehicle operating instructions.
Se cu re v e h ic le a g a in s t ro lling . - Never work under cab when partially tilted.
- On vehicles with manual transmission move shift lever to - Always tilt cab to end position and secure with safety brace.
neutral position.
- On vehicles with automatic transmission move selection lever
to position " n ".
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 15
AH60.80-N-0003-01A Notes on tilting the cab Models 673,674,675,676,677,678,
679, 950,952,953,954, 957, 970,971,
972, 973, 974, 975, 976
Additional Information
16
AR01.10-W-2400D Removing, installing engine 5,8.97
W 01.10-0014-09
1 Cap (engine 904.909- 911/922) 9 Connector (control unit)
2 Clutch compressed air line (engine 904.909-911/922) 10 Engine mounting
4 compressed air line connector (engine 904.903- 97 I/9ZZ) l ; steering line (return flow)
4 19Engine hoist 12 Steering line (pressure)
5 19 Chain block 13 Fuel line (feed)
6 Compressed air line (compressor) 14 Fuel line (return flow)
7 Shift rod (engine 904.909- 911/922) 15 Oil filler pipe
8 Wiring harness, line and bracket 16 AC compressor
W 01.10-0012-09
Additional Information
W01.10-0017-11
Modification notes
6.7.98 Enter engine number in FDOK after replacing engine Step 31 added Page 17
Danger Risk o f ex p lo sio n fro m gas. Risk o f N o fire, sparks, n a k e d fla m es o r sm oking. P a g e 13
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
Additional Information
18
8 Detach exhaust pipe (22) at engine brake Tie up exhaust pipe at frame
flap connection and transmission CDInstallation: clean sealing surfaces
9 Detach compressed air line (26) at engine II On engine with engine brake
brake cylinder
11 Detach electric cables at flame glow plug II On engine with flame starting system
and at solenoid valve
13 Detach electric cable (25) at generator (G1) [I Pay attention to color coding
and fixture
16.2 Detach shift lever with shift linkage (30) O n e n g in e 906 91(1/911
and bracket(31)atsupport(32)
A Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 21
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
17 Separate fuel lines (13,14) at fuel filter [I Collect fuel which flows out. Mark fuel
lines.
18.1 Slacken poly V-belt and take off [I On vehicle with air conditioning AR13.22-W-1202A
18.2 Detach AC compressor (16) with bracket at II On vehicle with air conditioning.
engine Do not separate refrigerant lines.
. Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
hydraulic fluid spraying out under high commencing work on hydraulic system.
pressure. Risk of poisoning from W ear protective clothes and eye
swallowing hydraulic fluid. protection.
20 Separate both hoses at the steering lines Collect hydraulicfluid which flows out AP46.00-W-4611A
(11.12) II Installation: top up hydraulicfluid and
bleed steering
24 Take off bracket at enqine mounts (10) DO Inspedt enaine mounts for wear,
replace if necessary
28 Check engine oil level at electric gage See operating instruction part 3
29 Start engine and observe oil pressure gage Start engine with starter for not more BE18.00-N-1001-01C
when engine idling than 90 seconds. Wait about 2 minutes
before repeating attempt at starting. Do
not rev up engine so long as no oil pressure
vindicated.
S The oil pressure gage should indicate
oil pressure afterabout 10seconds.
20
Additional Information
Repair products
A947 00-7-0001-01A Risk o f ex p lo sio n fro m ig n itio n o f fu e l, risk Fire, th e c re a tio n o f sparks, naked A D a n g er!
of poisoning if fuel is inhaled or swallowed lights and smoking prohibited.
and risk of injury if skin or eyes come into Only pour fuels into containers which
contact with fuel are suitable and are correspondingly
m arked.
Wear protective clothing when
handling fuels.
Additional Information
E ngines O M 9 0 A I A. 906 L A (m o d . doc. 904.0, 00 6 .0 ), FA 21
AS00.00-Z-0013-01A Risk of injury to skin or eyes from Before starting work on the hydraulic ^ Danger!
pressurized hydraulicfluid spraying out. system, depressurize the system. Wear
Risk of poisoning from swallowing protective clothing and safety glasses.
hydraulicfluid
Potential danger
Risk of injury - Ensure only authorized persons have access to hydraulic fluid.
Serious injuries can be caused to the skin or eyes when loosening - Seal disconnected lines and hoses and connections on the
hydraulic lines without depressurizing the system beforehand, subassemblies immediately with blind plugs.
due to the very high pressures (above 200 bar). Damage to the - Wear safety gloves, protective clothing and safety glasses.
skin may be caused if unprotected skin comes into contact with If it is not possible to wear safety gloves, the following points are
hydraulic fluid, particularly central hydraulic fluid (this is to be observed:
especially harmful to health). - Only allow hydraulic fluid to come into contact with the skin
for as short a time as possible, wash fluid off skin with soap
Risk of poisoning and water.
Anyone who swallows hydraulic fluid can expect to suffer - Change wet clothing as quickly as possible
sym ptom s o f p o iso n in g in clu d in g he ad ach es, dizziness, sto m ach
ache, vomiting, diarrhoea, cramps and unconsciousness First aid
Have the casualty drink plenty of water with activated charcoal
Safety measures/operating instructions additive.
B e fo re s ta rtin g w o r k o n h y d ra u lic system s th e y sh o u ld be A fte r s w a llo w in g la rg e r q u a n titie s .c o n s u lta d o cto r.
depressurized and the system must be emptied if necessary. If hydraulicfluid gets into the eyes, rinse out the eyes
- Do not pour hydraulic fluid into drinking containers. immediately with plenty of clean water/using a eye rinsing
- Ensure adequate ventilation, particularly in the case of central glass.
h y d ra u lic flu id . In th e e v e n t o f injuries to skin o r eyes fro m a je t o f hyd rau lic
fluid, consult a doctor Immediately.
R e p a ir products
Additional Information
22
1 Attach engine hoist (1) to the lifting
eye (2) of the coolant pump at the
front or to the connector and at the
rear left to the lifting eye (3).
Max. 30 inclination of engine when
lifting out or inserting.
W01.10-0011-06
m
If it is not possible to push the engine and the transmission
together, rotate starter ring gear sufficiently so that the
internal splines of the clutch plate are aligned with the
splines of the transmission shaft.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 23
AR01.10-W-2400F Removing, installing engine 12.6.98
W 01.10-1002-09
7 Bracket in frame 7 Connector (w iring harness)
2 Engine mount 8 Connector (engine wiring harness)
3 W iring harness 9 Fuel line
4 Exhaust pipe 70 Hydraulic fluid line (steering system)
5 Compressed air line (compressor) 11 AC compressor (air conditioning)
6 Clutch servo unit 12 O il filler line
m i HU Removing, installing
24
Additional Information
4 Detach hydraulic pump or propshaft With engine output at rear
9 Remove exhaust pipe (4) at engine brake CD Installation: clean sealing surfaces and
flap connection and at rear lifting eye inspect clip for wear; replace clip if
necessary
10 Detach wiring harness (3) at bracket (1) in ED Installation: attach wiring harness with
right frame longitudinal member cable straps
14 Slacken poly V-belt and take off On vehicle with air conditioning AR13.25-W-3200B
Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking.
poisoning from inhaling and swallowing Pour fuels only into suitable and Page 21
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
17 Separate fuel lines (9) at fuel filter ED Collect fuel which flows out. Mark fuel
lines an d tie up.
18 Remove oil filler line (12) ID Seal opening at oil filler hose
A Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
h y d ra u lic flu id sp ra y in g o u t u n d e r h ig h co m m e n cin g w o r k on h y d ra u lic system .
pressure. Risk of poisoning from W ear protective clothes and eye
swallowing hydraulic fluid. protection.
19 Separate both hoses at the hydraulic fluid Collect hydraulic fluid which flows out
lines (10) of the steering system f f i Installation: top up hydraulic fluid
20 Release and separate connector (7) of Tie up connector at frame so that it is not
wiring harness at MR (PLD) control unit damaged when lifting out the engine
D installation: secure connector
23 Detach transmission oil line (17) at engine [ I ] Collect transmission oil which flows out
25 U n s c re w bo lts a t b o th e n g in e m o u n ts (2)
33 Inspect engine oil level at electric gage See operating instructions part 3
A Danger Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 31
starting off when engine running. Risk of Wear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
Additional Information
26
Test data of engine oil pressure
0 Shift mechanism
Repair products
0 Gear shift
0 Gear shift
W26.60-1005-11
Additional Information
28
W26.60-1006-08
3 Detach line fixing (7) with hydraulic lines (1)from 5 D e ta ch g e a r h y d ra u lic s h ift c y lin d e r (5) fro m transm ission
transmission. with hydraulic lines (1) connected.
0 Do not open fixing clamp. 0 On transmission 715.320, also detach compressed-air line
and electrical connector from shift cylinder.
4 Detach gate hydraulic shift cylinder (6) from transmission On transmission 715.510, detach shift cylinder with bearing
with hydraulic lines (1) connected. bracket.
0 On transmission 715.320, press the shift cylinder
forwards and lift out backwards. 6 Install in reverse order.
Repair products
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9. 906 9). F4 29
1 Attach engine hoist (2) at the front at
the connection piece (1) and at the
rear left at the lifting eye (4).
Max. incline position of engine when
lifting out or inserting is 30.
6 Turn release bearing (5) until the tensioning pin (5.1) is in horizontal position.
m
Do not damage cables, connectors and attached parts.
m
If it is not possible to push the engine and the transmission together, rotate starter ring
gear sufficiently so that the internal splines of the clutch plate are aligned with the
splines of the transmission shaft.
W01.10-1005-03
Additional Information
30
AS00.00-Z-0005-01 A Risk of accident as a result of vehicle Secure vehicle to prevent it from Danger!
starting off when engine is running. Risk of moving off.
injury as a result of bruises and burns if you wear closed and close-fitting work
insert your hands into engine when it is clothes.
being started or when it is running. Do not grasp hot or rotating parts.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 31
AR01.10-W-24Q1A Removing, installing engine w ith transmission 15.9.97
ENGINE 904.905/906/907/921
W01.10-0016-09
Additional Information
13 Bolt 27 A ir intake hose (compressor)
14 Engine mounting 28 Wiring harness (generator)
20 Exhaust pipe 29 Ground cable
21 Clam p 30 Compressed air line (engine brake cylinder)
22 Rear lifting eyes 31 Starter cable
23 I S Engine hoist 32 Electric control cable (starter)
23.1 I S Shackle
24 I S Chain block M1 Starter
25 Front lifting eye (coolant pump) G1 Generator
26 A ir intake hose (turbocharger)
5 P ro p e lle r shaft
7 Connector (speedodrive)
33 Bolt
34 Nut
35 R ear transm ission m o u n tin g
Modification notes
6.7.98 Enter engine number in FDOK after replacing engine Step 36 added Page 32
A Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 13
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
2 Tilt cab
8 Detach exhaust pipe (20) at engine brake ED installation: clean sealing surfaces
flap connection
9 Detach compressed air line (30) at engine EE On engines with engine brake
brake cylinder
^ Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking, Page 21
poisoning from inhaling and swallowing pour tuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. W ear protective clothing when handling
fuel.
18 Separate fuel lines (9,10) 2 At fuel priming pump and at fuel filter.
Collect fuel which flows out.
Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
hydraulic fluid spraying out under high commencing work on hydraulic system.
pressure. Risk of poisoning from W ear protective clothes and eye
swallowing hydraulic fluid. protection.
21 Separate both hoses at the steering lines 2 Collect hydraulic fluid which flows out
24 Attache engine hoist (23) at rear left at Insert shackles (23.1) as intermediate
lifting eye (22) pieces so that the engine hoist does not run
over the cylinder head cover
13 Shackle WH58.30-Z-1002-07A
25 Attach chain block (24) at rear right at @ Insert shackles (23.1) as intermediate
lifting eye (22) and tension chains at pieces so that the engine hoist does not run
engine hoist and chain block over the charge air manifold.
Secure engine to prevent it tipping.
2 Shackle WH58.30-Z-1002-07A
34
Additional Information
28 Unscrew bolt (33) at rear transmission ELI Installation: replace nut (34)
mounting (35)
29 Unscrew bolts (13) on both sides at engine E Inspect engine mounts for wear,
mounts (14) replace if necessary
30 Lift out engine with transmission H J Max. tilt of engine with transmission
w h e n liftin g o u t o r insertin g 30
34 Start enqine and observe oil pressure qaqe @ Start engine with the starter for not BE18.00-N-1001-01C
when engine idling more than 90 seconds. Wait about 2
minutes before repeating attempt at
starting. Do not rev up engine so long as no
oil pressure is indicated.
GO The oil pressure gage should indicate
oil pressure after about 10 seconds
0 Propeller shaft
M 12X1.5 Nm 92
Additional Information
36
AR01.10-W-2401B Removing, installing engine w ith transmission 15.9.97
Additional Information
Modification notes
6.7.98 Enter engine number in FDOK after replacing engine Step 32 added Page 37
Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 13
poisoning and burns from swallowing W ear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes ey e p ro te c tio n . P o u r b a tte r y e le c tro ly te
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
38
Additional Information
6 Remove fan shroud AR20.40-W-68Q0A
8 Detach exhaust pipe (22) at engine brake Tie up exhaust pipe at frame
flap connection and transmission E Installation: clean sealing surfaces
9 Detach compressed air line (26) at engine E On engine with service brake
brake cylinder
11 Detach cable at flame glow plug and at E On engines with flame starting system
solenoid valve
13 Detach electric cable (25) at generator (G1) E Pay attention to color coding
and fixture
Danger Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 21
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
16 Separate fuel lines (18,19) at fuel filter E Mark fuel lines and collect fuel which
flo w s o u t
17.1 Slacken poly V-belt and take off B On vehicle with air conditioning AR13.25-W-3200B
Danger Risk of injury to skin or eyes as a result of Render system pressureless before Page 22
hydraulic fluid spraying out under high commencing work on hydraulic system.
pressure. Risk of poisoning from Wear protective clothes and eye
swallowing hydraulic fluid. protection.
20 Separate both hoses at the steering lines Collect brake fluid which flows out AP46.00-W-4611A
(16,17) E Installation: top up brake fluid and
bleed steering
21 Remove lock and pull out clutch line (12) at Collect brake fluid which flows out
transmission E Installation: replace seal at clutch line
25 Detach bracket at engine mounts (15) HHI Inspect engine mounts for wear,
replace if necessary
29 Inspect engine oil level at electric gage See operating instructions part 3
30 Start engine and observe oil pressure gage Start engine with starter for not more BE18.00-N-1001-01C
with engine idling than 90 seconds. W ait about 2 minutes
before repeating attempt at starting. Do
not reve up engine so long as no oil
pressure is indicated.
LLl The oil pressure gage should indicate
oil pressure after about 10 seconds.
Additional Information
40
S Complete mechanical transmission
0 Propellor shaft
M12X1.5 Nm 92
Do not allow the brake fluid to come into contact with the Brake fluid is colorless to yellow in color and therefore may
paintwork of the vehicle as it contains elements which act as be easily confused with mineral oil products. For this reason,
a solvent on the paint. Should brake fluid come into contact always pour brake fluids out of the original cans and store it
w ith t h e p a in tw o rk d esp ite all p re ca u tio n s h aving b e en sep ara te ly fro m m in e ra l oils a n d o th e r fluids.
taken, the moistened area should be rinsed immediately
with plenty of water (do not attempt to rub off brake fluid). Disposal instructions for workshops located in Federal
Republic of Germany see:
B ra k e flu id is g re a tly h ygroscopic, in o th e r w o rd s it absorbs " U m w eltschutz H andbuch f r K fz -R c p a ra tu rb c tric b c "
moisture from the air, as a result of which the boiling point is Publisher: Verband der Automobilindustrie e.V. (VDA)
lowered. For this reason, brake fluid must only be stored in D-60625 Frankfurt am Main, Westendstrae 61
closed and properly sealed containers (original cans).
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 41
1 Attach engine hoist (1) to the lifting
eye (2) of the coolant pump at the
front or to the connection piece and
to t h e liftin g e ye (3) a t th e
transmission.
W01.10-0010-06
Additional Information
42
A R 01.00-W -0001A inspecting engine for dust dam age 30.11.95
Removing
a Inspecting
2 Inspect intake tract between air cleaner CO Severe dust deposits In the elbows of
and engine for dust deposits the intake pipes and hoses are a reliable
indication of dust damage.
A very fine film is permissible on engines
with oil bath air cleaner.
3 Inspect pistons and cylinder wall for wear GO The wear patterns of the stems of the
(dust d a m a g e ) pistons a n d th e h o ning p a tte rn s o f th e
cylinders make it possible to recognize
damage caused by severe dust deposits.
If wear exists j
AH01.40-N-0001 -01A Notes for assessing wear of cylinder wall if Engines 904, 906, 541,542 m
dust damage present
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 43
Cylinder walls and cylinder liners with dust damage
The traces of machining from honing are only very faintly visible or not at all. If the wear is
well advanced, a wear step can be felt at the reversal point of the first piston ring.
m
Dust damage is caused by poor sealing, splits, chafing damage of the intake lines, seals and
hoses.
When carrying out repair and service work, make a careful inspection of intake lines, seals
and hoses, also at points not easily accessible.
ffl
The machining grooves at the circumference are intentional recesses which are filled with oil
and contribute to better lubrication.
W 0 3 .10-0012-01
Additional Information
44
AR01.00-W-0200A Inspecting cylinders w ith light probe 3.7.97
W 0 1.00-0018-06
In sp e ctin g
3 Rotate crankshaft with the cranking device Position piston of cylinders to be inspected
toBDC
5 Inspect cylinder wall and piston crown ( 3 Cylinder walls must not reveal any Page 43
scorch streaks and rubbing streaks.
Individual slight drawing scores are not
critical.
Additional Information
Engines O M904 LA, 906 LA (mod des. 904.9,906.9), F4 45
S Timing case
@ Timing case
Additional Information
46
1 Remove noise encapsulation below the flywheel housing.
3 Attach E l cranking and blocking device (2) tight to flywheel housing with bolts (4).
HI Cranking and blocking device (2)can be blocked by inserting the pin (3).
@ Cranking and blocking device (2) must be removed before starting the engine.
W 03.30-0001-02
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 47
AR01.00-W-1200A Testing compression pressure 3.7.97
W 01.00-0019-09
1 Nozzle holder combination 7.1 S I Compression recorder
2 Bolt 7.2 S I Diagram sheet
3 Spherical washer 7.3 S I Adapter
4 Tensioning arm 8 Seal
5 S I Connector
6 End cover fo r c o n sta nt th ro ttle S10 S ta rt sw itch
S JI Stop switch
Revisions
7.7.98 Tightening torque for bolt of tensioning arm at cylinder Step 5 Page 48
head modified
121 R em oval
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
48
Additional Information
3 Warm engine up to operating temperature (XI Coolant temperature approx. 70 to
95 C
m 904 589 01 21 00
6 Attach compression recorder (7.1) to the I S See operating instructions for 001 589 78 2100
c o n n e cto r (5) connection of compression recorder
m 904 589 01 21 00
Testing
Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 31
starting off when engine running. Risk of Wear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
SI Installation
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 49
Test data of compression pressure
a r
904 589 01 21 00
Connector
Additional Information
50
AR01.20-W-5014A Removing, installing cylinder head cover 17.7.95
W 01.20-0001-06
30 Hydraulic lines
31 Securing clips
32 Mounting plate
33 Bolt
HU EU Removing, installing
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 15
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 51
3 Detach hydraulic lines (30) with the On engine 906.920-923 with "hydraulic"
mounting plate (32) and the securing clips transmission shift code GS3
(31) at the engine and place to the side E Do not separate hydraulic lines
5 Take off cylinder head cover (5) E Installation: replace sealing washers (2)
and gasket (6) of cylinder head cover.
Inspect gasket (3) between cylinder head
cover and boost air manifold, if necessary
1
replace gasket (3)
Additional Information
52
AR01.20-W-9750A Removing, installing oil separator 28.8.95
W 0 1 .20-0005-06
m m Removing, installing
Additional Information
En g in es O M 9 0 4 LA, 906 L A (m o d . des. 904.9, 90G.9), F4 53
AR01.30-W-5461A Removing, installing protective sleeve 17.7.95
ENGINE 904.905/906/907/908/909 /910 /911 /921 /922, 906.910 /911 /920/921 /922 /923 /940/941
1 Nozzle holder combination
2 Protective sleeve
3 O-ring
4 E l Slotted nut wrench
Modification notes
7.7.98 Tightening torque and thread diameter for protectice Step 3 Page 54
sleeve at cylinder head added
Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 56
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
o ut. Risk o f p o iso n in g fro m s w a llo w in g ca p s lo w ly a n d a llo w th e pressure to
coolant release. Do not pour coolant into
containers for drinks.
W ear protective gloves, protective clothes,
a n d e y e p ro te c tio n .
4 Remove O-rlng (3) from the cylinder head Q ] Installation: replace O-ring (3) and coat B R00.45-Z-1018-06A
with acid-free grease
54
Additional Information
5 Install in the reverse order
S Cylinder head
M 14x1 Nm 45 45
S
V 904 589 00 07 00 J
Repair products
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 55
AS20.00-Z-0001-01A Risk of injury to skin and eyes from Do not open the cooling system unless A Danger!
scalding from hot coolant which splashes the coolant temperature is below 90
o ut..R isk o f p o iso n in g fro m sw a llo w in g C. O p e n cop s lo w ly a n d a llo w th e
coolant. pressure to release.
Do not pour coolant into containers
for drinks.
Wear protective gloves, protective
clothes, and eye protection.
Coolant composition
Passenger car and commercial vehicle engine (normal case): A concentration of anticorrosion/antifreeze agent higher than
50 % by volume water and 55 % by volume should not be used as the maximum antifreeze
50 % by volume anticorrosion/antifreeze agent. protection is thus reached. An even higher concentration again
See M B Specifications for Service Products for differing coolant reduces the antifreeze protection and impairs heat dissipation.
composition for commercial vehicle engines.
Water
Purposes of anticorrosion/antifreeze agent Use water which is clean and not too hard. Drinking water
Corrosion and cavitation protection for all components in the frequently, but not always, satisfies the requirements. The
cooling system contents of dissolved substances in the water can be of
Antifreeze protection importance for the occurrence of corrosion. In cases of doubt,
Increasing boiling point so that the coolant does not evaporate analyze the water. See MB Specifications for Service Products for
so rapidly. Ejection of coolant is avoided at high coolant fresh water regulations.
temperatures.
Operation of monitoring of coolant
Antifreeze protection Inspect coolant for resistance to low temperatures before the start
50 % by volume of anticorrosion/antifreeze concentration offers of the cold season of the year.
antifreeze protection down to approx. -37 C. In countries with high ambient temperatures, inspect the
A higher concentration is only practical at even lower ambient anticorrosion/antifreeze concentration once a year.
temperatures. The corrosion protection in the coolant is reduced during
55 % by volume of anticorrosion/antifreeze concentration offers operation. Such coolants have a severely corrosive effect.
antifreeze protection down to approx. -45 C. The maximum permissible period of use of the coolant is for
passenger car and commercial vehicle engines (normal case)
3 years.
See MB Specifications for Service Products for the period of use
for differing coolant composition for commercial vehicle engines.
Additional Information
56
Disposing of coolants
Before pouring fresh coolant into the system, flush the used Observe legal regulations and local wastewater regulations.
coolant out of the cooling system. Clean cooling system if severe For workshops located in the Federal Republic of Germany see:
soiling or oil contamination exist. "Umweltschutz-Handbuch fr Kfz-Reparaturbetriebe "
(Environm ental protection m anual for vehicle repair
workshops)
Publisher: Verband der Automobilindustrie e.V. (VDA)
D-60625 Frankfurt am Main, Westendstrae 61
Additional Information
)*- 'U ' Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 57
AR01.30-W-5800A Removing and installing cylinder head 17.7.95
W 0 1 .30-0017-06
Additional Information
58
W O l.30-0018-09
MM Removing, installing
Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Page 56
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
and eye protection.
12 Remove connection piece (8) at cylinder EEInstallation: replace connection fitting Page 63
head (18) and at coolant pump (10) and gasket (7)
IS 422 589 02 09 00
16 Attach lifting device (21) at cylinder head @ Do not damage installed nozzle holder
(18) and take off cylinder head combinations
HIInstallation: fit on cylinder head over
centering sleeves (20)
IS 904 589 01 63 00
17 Take off cylinder head gasket (19) Hi Seal oil and coolant holes at crankcase.
Clean and inspect crankcase contact
surface.
Inspecting
19 Measure length of shank of cylinder head If the maximum shank length (L) is BE01.30-N-1001-01B
bolts (17) exceeded (
20 Inspect cylinder head (18) for cracks and HI If problem exist, replace cylinder head
damage
21 Inspect flatness of cylinder head (18) and Flatness of cylinder head contact surface BE01.30-N-1002-02B
crankcase contact surface with knife-edge
straightedge
HI If u n e v e n |
60 Additional Information
face contact surface of cylinder head Page 69
face contact surface of crankcase
23.1 Check engine oil level with dipstick On engine 904.905- 907/921 WH0101.40
23.2 Check engine oil level at electric gage On engine 904.909- 911/922 and
906.910/911 /920- 923/940/941
See ATEGO operating instructions part 3
* D anger Risk o f accident as a resu lt o f vehicle Secure vehicle to prevent it starting off. Page 31
starting off when engine running. Risk of Wear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
bein g started o r w h e n it is run ning.
25 Start engine and observe oil pressure gage @ Crank engine with starter for not more BE18.00-N-1001-01C
when engine idling than 90 seconds. Wait about 2 minutes
before repeating attempt at starting.
Do not rev up engine so long as no oil
pressure is indicated.
CD The oil pressure gage should indicate
oil pressure after about 10 seconds.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 61
Test data of crankcase
@ Cylinder head
2nd stage Nm 70
5th stage 90
6 th stage X 90
Additional Information
62
422 589 02 09 00 J \ 904 5890163 00 J
Wrench socket lifting device
W 20.10-0014-11
Additional Information
Engines OM904 LA, 906 LA (mod, des. 904.9, 906.9), F4 63
AR01.30-W-5800-07A Tightening specification of cylinder head
bolts
0 Cylinder head
2nd stage Nm 70 70
5th stage 90 90
6th stage 90 90
Oil cylinder head bolts with engine oil and tighten with I S socket a
wrench bit. If the tightening torque has been exceeded at a cylinder head
bolt, unscrew cylinder head bolts, inspect shank length (replace
cylinder head bolt if necessary) and tighten, beginning with stage
It is important to observe all the tightening torque stages and to 1.
tighten the bolts in the correct sequence in order to achieve
uniform contact pressure of the cylinder head gasket; see Cylinder head bolts are not retightened.
tightening diagram.
.D o D o D o D o .
Additional Information
64
Shown on engine 906
W 0 1 .3 0 -0 0 2 0 -0 4
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 65
AR01.50-W-1000A Removing, installing decompression brake valve 1.9.95
Additional Information
66
ENGINE 904.905/906/907/909/910/911/921 /922,906.910/911/920/921 /922/923/940/941
ENGINE 904.908/923 w ith CODE (MB1) Engine brake with decompression brake valve
1 End cover
2 O-ring
3 Seal
4 Piston
5 Locking wedge
6 Top spring plate
7 Spring
8 Bottom spring plate
9 Valve
11 Spacer
4 Piston
5 Locking wedge
6 Top spring plate
7 Soring
12 Pliers
13 W ] Spring retainer depresser
15 W1 M agnetic pin
W 0 1 .50-0010-06
Additional Information
Engines OM904 LA, 906 LA {mod. des. 904.9. 906.9). F4 67
Engines 904.909-911/922, AR07.03-W-6831C
906.910/911/920-923/940/941 and engine
904.905-908/921 as of end no. 040488
3 Remove end cover (1) at cylinder head (10) IT!Installation: replace O-ring (2)
4 Insert a suitable spacer (11) between valve [Li Height of spacer approx. 5.3 mm
disk and base
D 442 589 05 63 00
8 Relieve the load on the spring, remove top Q ] Do not transpose top spring plate and
spring plate (6), spring and bottom spring Sring guide.
plate (8) lU Installation: Mount spring guide,
spring and spring retainer on the valve
stem of the decompression brake valve.
9 Turn cylinder head (10) and pull out valve Mark valve.
(9) B Installation: oil valve stem, push in
valve and place spacer (11) (height approx.
5.3 mm) below valve disk.
Additional Information
68
AR01.30-W-7162A Inspecting, facing cylinder head contact surface 21.11.95
W 0 1.30-0019-06
E3 R e m o v in g
1 Remove cylinder head On engine 904.905- 907 /909- 911 /921 /922 Page 58
and 906.910/911/920- 923/940/941
O n e n g in e 904.008 AR01.30-D-S800D
Inspecting
5 Measure cylinder head overall height (H) [ I ] If measurement is less than permissible 8E01.30-N-1001-02B
and variation of parallelism from top to minimum height J,
bottom contact surface
Machining
7 Face cylinder head contact surface @ Surface quality (peak-to-valley height BE01.30-N-1003-02B
(combustion chamber side) R3z / waviness W t ) of cylinder head contact
surface must be maintained
El Measuring
9 Once again measure cylinder head overall Height of cylinder head BE01.30-N-1001-02B
height and variation of parallelism of top
to bottom contact surface
10 Insert valves (1, 2) into the cylinder head IHPay attention to marking of valves
11.1 Measure valve setback (B) to cylinder head On engine 904.905-908/921 Page 72
Measure valve setback at both inlet valves BE05.30-N-1001-01B
and at exhaust valve and note
HI 001 589 53 21 00
HI 343 589 00 40 00
11.2 Measure valve setback (B) to cylinder head, On engine 904.909- 911/922 and Page 73
and permissible difference (C) between 906.910/911/920-923/940/941
both inlet valve stems
HI 001 589 53 21 00
HI 363 589 02 21 00
12 Measure projection of guide bolt (6) from On engine 904.905- 908/921 BE05.30-N-1003-04B
cylinder head and correct
m Installing
13 Install constant throttle (3) On engine 904.905- 907/909- 911 /921/922 Page 66
and906.910/911/920- 923/940/941
On engine 904.908 with constant throttle
Code MB1
Additional Information
70
Test data of cylinder head
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 71
\ f \
a r
m
Valve disk (3) should be making contact with valve seat.
2 Mount [ S dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move H3 dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
If the reading obtained (A) is not within the permissible tolerance, inspect valve seat
ring or the valve disk.
Additional Information
72
AR05.30-W-4100-01C Measuring amount by which valve stands
back to cylinder head
E
V a lv e disk (3) s h o uld be m a k in g c o n ta c t w ith v a lv e seat.
4 Move dial gage (1) sufficiently until the tracer pin istouching the valve disk (3).
m W05.30-0060*01
If the reading obtained (A) is not within the permissible tolerance, inspect valve seat
ring or the valve disk.
Additional Information
E n g in e * O M 9 (M LA, 906 L A (m o d . des. 904.9, 90G.9), F4 73
5 A tta c h 1311d ial g a g e ( i ) t o I S j th e dial
g a g e h o ld e r (4) a n d m o u n t on t h e to p
c o n ta ct su rface o f t h e cy lin d e r h e ad .
ffl
Permissible difference (C) between
both inlet valve stem ends (5) must not
be exceeded.
Additional Information
74
AR01.40-W-9202A Measuring cylinder bores 17.11.95
ENGINE 904.905/906/907/908/909/910/911/921/922/923,906.910/911/920/921/922/923/940/941
1 Crankcase
2 S I Dial gage
3 [ 0 Quick calipers for internal
m easurem ents
A ,B Directions o f measurement in
crankcase
I M easut iu y jo in ts a t to y reve rsa l p o in t
of first piston ring
n Measuring points in middle o f cylinder
wall
W 01.40-0034-06
1 Remove cylinder head Engine 904.905- 907/909- 911 /921 /922 and Page 58
906.910/911/920- 923/940/941
0 Inspecting
3 In sp e ct cy lin d e r w a lls or cylin d er lin ers S3 C ylin d er w a ll or cylin der lin ers m ust n o t
reveal any scorch streaks. Individual slight
drawing streaks are not critical.
El Measuring
4 Set dial gage (2) and quick calipers (3) with E l Preload 5 mm BE01.40-N-1001-02B
the micrometer to the inner 0 of the
cylinder liner
E 001 589 53 21 00
IS Micrometer WH58.30-Z-1027-12A
5 Measure cylinder wall or cylinder liner E Measure in the unworn area (top land BE01.40-N-1001-02B
inner 0 and set dial gage (2) to 0" zone) above the top reversal point of the
first piston ring. Directions of
measurement in direction of travel (A) and
in transverse d irectio n (B).
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 75
6 Measure difference in diameter of cylinder [0 Measure wear of cylinder wall or BE01.40-N-1003-02B
liner cylinder liner at measuring points (1, II) in
direction of travel (A) and in transverse
direction (B).
Additional Information
76
AR01.40-W-9211A Flex-honing cylinder wall 4.12.95
1 Crankcase
2 IS Honing brush
3 IS Hand drill
W 0 1 .40-0001-06
Machining
4 Insert pieces of foam through the cylinder H I Cleaning rags do not adequately ab
walls over the crankshaft and the bearings sorb grinding residues and lubricant.
(protection against grinding residues)
5 clamp honing brush (2 ) into hand drill (3) 00 use honing oil, viscous engine oil,
and immerse in lubricant petroleum or diesel fuel.
Fit guard or guard box onto crankcase
contact surface (1) in order to prevent
soiling of surrounding area and of clothes.
6 Insert hand drill (3) with honing brush (2) @ Do not operate drill at a speed of more
into the cylinder bore to be machined than about 200 rpm (risk of honing brush
snapping off).
7 Move honing brush (2) evenly up and down 3 ] Change direction as soon as about 1/4
of honing brush projects at top or bottom.
Machining time about 1 to 2 minutes.
8 Take out honing brush (2) and inspect H I Aim for a grinding pattern of approx.
surface structure 45 and a mat appearance.
If the surface is glossy I
repeat honing
Additional Information
78
AR01.40-W-9271A Widening cylinder bore in crankcase 3.11.95
1 Crankcase
W 01.40-0002-06
Machining
2 Align cylinder wall relative to boring E Using centering device above reversal
machine point of 1st piston ring.
3 Clamp boring tool and widen cylinder bore B If several cylinder liners are installed,
in several operations pay attention to sequence of work in order
to avoid excessive thermal stresses.
Engine 904; cylinder bore 2-4-1-3
Engine 906; cylinder bore 1-3-5-2-4-6
Widen to leave approx. 0.05 mm of the
desired final dimension (cylinder liner bore
0).
E Settings for honing machine.
Working pressure (p): 2.5 to 3.0 bar
Speed (n): 60to100rpm
Honing angle (a): 40 to 60
No. of strokes; 30 to 40
4 Machine cylinder bore to final dimension E Set boring tool to the respective
(precision boring) diameter using the measuring device.
5 Bore seat of liner collar E Use drilling tool with 90 cutting angle
Additional Information
E n g in e s O M 9 0 4 LA . Qflfi L A (m o d des 9 4.S, 90 6 .9 ), F4 79
Distance between cylinder liner collar seat BE01.40-N-1009-02B
and contact surface of crankshaft bearing
cap (D).
Additional Information
80
Test data of crankcase
Peak-to-valley height pm 16 16
(Rz)
BE01.40-N-1015-02B Bore for cylinder liner collar In Concentricity mm 0.060 0.060
crankcase
Peak-to-valley height pm 25 25
(Rz)
BE01.40-N-1017-02B Overlap of cylinder liner to max. mm 0.040 0.040
machined crankcase
Fig. see - -
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 81
AR01.40-W-9272A Removing cylinder liner 20.11.95
ENGINE 904.905/906/907/909 /910 /911 /921 /922,906.910 /911 /920 /921 /922 /923
ENGINE 904.908/923 In M ODEL 668. 670
ENGINE 906.940/941 in M ODEL 957
W 01.40-0004-06
12 Removing
3 Align cylinder wall to boring machine (3) E Using centering device above reversal
point of 1st piston ring.
4 Clamp boring tool and widen cylinder liner E If several cylinder liners are removed,
(2) in several operations to half of the wall pay attention to sequence of work in order
thickness to avoid excessive thermal stresses.
Engine 904 cylinder bore 2-4-1-3
Engine 906 cylinder bore 1-3-5-2-4-6
5 Cylinder liner (2) as far as about 0.2 mm DOThe liner collar detaches with this
below the outer diameter setting of the boring tool.
Additional Information
82
Test data of crankcase
BE01.40-N-1001-02B Cylinder wall or cylinder liner inner Code letter A mm 101.985-101.991 101.985-101.991
0
Code letter B mm 101.992-102.008 101.992-102.008
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 83
AR01.40-W-9273A Installing cylinder liner 20.11.95
W01.40-0035-09
1 Crankcase A Crankcase height
2 Cylinder liner B Bore diam eter o f cylinder liner
3 M arking surfaces on crankcase C Bore diam eter o f cylinder liner collar
m Installing
1 Widen cylinder bore in crankcase (1) E Only if no cylinder liner (2) is fitted. Page 79
2 Remove cylinder liner (2) CDOnly if no cylinder liner (2) is fitted. Page 82
3 Measure bore and collar seat in crankcase Bore 0 (B) of cylinder liner BE01.40-NA 007-02B
(1)
6 Place crankcase (1) on the press and align ES Workshop press WE58.40-Z-1001-12A
8 Press in cylinder liner (2) until it projects CDUse a suitable plate for pressing in.
approx. 20 mm Inspect collar seat for abrasion (arrow) and
clean with compressed air if necessary.
84
Additional Information
10 Face contact surface of crankcase (1) Pay attention to undersize stages of BE01.40-N-1006-02B
crankcase height, height (A) measured
fro m m ain b e a rin g shell seat to co n ta ct
surface of cylinder head
13 Clamp in boring tool and widen cylinder S If several cylinder liners are fitted, pay
liner (2) in several operations attention to sequence of work in order to
avoid excessive thermal stresses.
Engine 904 cylinder bore 2-4-1-3
Engine 906 cylinder bore 1-3-5-2-4-6
Widen leaving approx. 0.05 mm of the
desired final dimension (bore 0 of cylinder
liner).
15 Gage adjacent walls and re-hone, if @ Pressing in can result in changes in the BE01.40-N-1001-02B
necessary structure which result In a slight change in
the inner 0 of the cylinder wall (cylinder
shap e) o f th e a d ja c e n t cylinders.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 85
Test data of crankcase
BE01.40-N-1001-02B Cylinder wall or cylinder liner inner Code letter A mm 101.985-101.991 101.985-101.991
0
Code letter B mm 101.992-102.008 101.992-102.008
Additional Information
86
Repair products
BROO 4 5 -7 -1 0 1 8 -0 6 A A T E g rease -
WE58.40-Z-1001-12A Fixed installation workshop press 651, e.g. make Matra-Werke GmbH, D-60314 Frankfurt/Main
BE01.40-N-1001-02B Cylinder wall or cylinder liner inner Code letter A mm 101.985-101.991 101.985-101.991
0
Code letter B mm 101.992-102.008 101.992-102.008
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 87
Box "6 ": at last cylinder
No marking means standard crankcase without cylinder
liners".
If the box is marked with the marking "-.3'7',-.6 /-.9",thisis
a crankcase with a reduced crankcase height (undersize).
If the box is additionally marked with the marking Z",
cylinder liners are installed in the crankcase.
Example: Marking "-.3" to indicate reduced crankcase height.
Marking "-.3 Z" to indicate reduced crankcase height
and cylinder liners fitted.
Additional Information
88
AR01.45-W-7500A Removing and installing oil sump 17.7.95
EN GIN E 904.905/906/907/921
OH filler pipe
Gasket
O il sump
Bolt
Seal
O il drain plug
Noise encapsulation
W 01.45-0001.06
Modification notes
M M Removal, installation
1 Remove noise encapsulation (7) at the oil CDInstallation: quick-locks must engage
sump properly.
4 Remove oil sump (3) EDInstallation: Clean oil sump and contact
surface at crankcase.
Replace gasket (2); pay attention to instal
lation position.
7 Start engine and check oil pressure gauge Do not crank engine for more than BE18.00-N-1001-01C
at Idle speed 90 seconds with starter. Repeat starting
operation after waiting for approx.
2 minutes.
Do not rev up engine before oil pressure is
indicated.
[ 3 The oil pressure gauge should indicate
oil pressure a fte r a p p ro x . 10 seconds.
@ Oil sump
Additional Information
90
AR01.45-W-7500C Removing and installing oil pan 3.7.97
ENGINE 904.909 /910 /911 /922, 906.910 /911 /920 /921 /922 /923
7 Oil pan
2 Gasket
3 Bolts
4 OH filler line
5 Seal
6 Oil drain plug
7 Engine wiring harness
W01.45-0005-06
Modification notes
5 Detach oil pan (1) Clean oil pan and contact surface of
crankcase.
CD Installation*, replace gasket (2), pay
a tte n tio n to in s ta lla tio n p o sitio n
Danger Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 31
starting off when engine running. Risk of W ear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
0 Oil pan
Additional Information
92
AR01.60-W-8200A Removing, installing timing case 17.7.95
W01.60-0006-06
M o d ific a tio n n o tes
5 Unscrew bolts (7) at oil pan (8) in the As of engine end no. 004 313 up to
area of the timing case (2) engine end no. 004 449 one bolt (2) was
shortened; pay attention to installation
position at rear left of oil pan (compressor
side)
6 Slacken remaining bolts (7) at oil pan (8) @ Do not damage oil pan gasket,
and lower oil pan (8) if necessary J
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 93
Engine 904.909- 911/922 and Page 91
906.910/911 /920- 923/940/941
8 Clean contact surfaces at timing case (2) IXI Installation: coat contact surfaces at BR00.45-Z-1010-01A
and at crankcase timing case with sealant.
9 Replace radial seal (9) DU Replace radial seal only if timing case AR03.20-W-3063A
(2) installed as installation dimension is
related to crankshaft.
@ Timing case
@ Oil pan
Repair products
Additional Information
94
AR01.60-W-8200F Removing, installing timing case 25.6.98
4.1 Take off cover plate (1) together with Except with rear engine output
gasket (2) at timing case (7)
4.2 Remove engine output at timing case (7) With rear engine output
7 Detach transmission oil lines (12) at timing E E Collect transmission oil which flows out
case (7) and crankcase
10 Unscrew bolts at oil pan (11) in area of 0 Bolt of oil pan to crankcase BA01.45-N-1001-01B
timing case (7)
n Slacken remaining bolts at oil pan (11) and Do not damage oil pan gasket (10), If
lower oil pan necessary J
13 Clean contact surfaces at timing case (7) CDInstallation: coat contact surfaces at B R00.45-Z-1010-01A
and crankcase timing case with sealant
14 Replace radial seal (17) CD Replace radial seal only if timing case AR03.20-W-3063A
(7) installed
0 Oil pan
0 Timing case
Repair products
Additional Information
96
AR03.10-W-7021A Removing, installing pistons 21.11.95
ENGINE 904.905/906 /907/909 /910/911 /921 /922, 906.910 /911 /920 /921 /922 /923
ENGINE 904.908 /923 in MODEL 668, 670
ENGINE 906.940/941 in MODEL 957
1 Piston
2 Piston pin
3 Circlip
4 Conrod
5 Conrod bearing cap
6 Conrod bolt
7 Conrod bearing shells
W 03.10-0005-06
1 Piston
2 Piston pin
4 Conrod
5 Conrod bearing cap
7 Conrod bearing shells
ft Dii spray nn?7/p
W 03.10-0006-06
Additional Information
@ 5 ^ Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 3
1 Piston
6 Conrod bolt shank length (L)
9 Tensioning strap
A Piston projection
W 0 3 .10-0007-06
EH Removing
1 Remove cylinder head Engine 904.905- 907/909- 911 /921/922 and AR01.30-W-5800A
906.910/911 /920- 923/940/941
3 Use a scraper to carefully remove HITo avoid damaging the piston rings
combustion residues above the top land when removing the pistons.
zone in the cylinder wall
4 Remove conrod bearing caps (5) CDMark conrod bearing caps and conrod
to each other.
@ D o n o t d a m a g e cracked c o n ta ct
surface. If damaged |
replace conrod.
6 Mark conrod bearing shells (7) to conrod [DEngines have different conrod bearing
bearing cap (5) and conrod (4) and remove shells in the conrod bearing cap and
conrod.
7 Remove piston pin (2) and take out conrod HIClamp conrod with piston; use soft
(4) protective jaws.
Additional Information
4
8 Measure conrod bolts (6) S If the maximum shank length (L) is BE03.10-N-1014-01B
exceeded J,
a Inspecting
10 Inspect piston rings for spalling of the E Replace damaged piston rings. Page 11
coating
12 Assign piston to cylinder bore E Markings are stamped on the piston Page 9
crown.
m Installing
14 Assemble oiston (1) and conrod (4) E Oil piston pin and press in by hand
17 Insert conrod bearing shell (7) in conrod (4) E Pay attention to marking. Lug on BE03.10-N-1001-01B
and oil contact surface conrod bearing shell should be located in
the slot of the conrod.
18 Insert piston (1) into the crankcase until the E Direction arrow on piston crown should
tensioning strap (9) is touching the face forward (opposite direction of force)
crankcase and the cracked contact surface at the
conrod (4) points toward the camshaft or
unit pump.
19 Press piston (1) into the crankcase E Until conrod bearing shell (7) makes
contact with conrod journal of crankshaft.
20 Attach conrod (4) and conrod bearing cap 0 Bolt of conrod bearing cap to conrod BA03.10-N-1001-01B
(5) to the crankshaft
E n g in e 904.908/923 A R 0 1 .3 0 D 5800D
Fig. see - -
Additional Information
6
Test data of piston
0 Conrod
3rd stage 90 90
541 589 01 21 00
y v y 000 589 38 31 00
Additional Information
Engines OM904 LA, 906 LA {mod. des. 904.9,906.9), F4 7
AH01.40-N-0001-01 A Notes for assessing wear of cylinder wall if Engines 904,906,541,542 ffl
dust damage present
m
Dust damage is caused by poor sealing, splits, chafing damage of the intake lines, seals and
hoses.
When carrying out repair and service work, make a careful inspection of intake lines, seals
and hoses, also at points not easily accessible.
AH03.10-N-0001-01A Notes for assessing wear to pistons in the Engine 541, 542,904,906 a
case of dust damage
Piston s w ith o u t d u st d a m a g e
The contact surface of the piston stem is visible over a large area and the machining grooves
can still be recognized within this area.
m
The machining grooves at the circumference are intentional recesses which are filled with oil
and contribute to better lubrication.
W 0 3 .10-0013-0!
AR03.10-W-7021 -03A Assigning piston to cylinder bore
BC mm 101.790-101.799 101.790-101.799
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 9
m
Measure projection between piston crown and contact surface of crankcase without
cylinder head gasket fitted on.
The measurement has to be carried out in the direction of the piston pin in order to
eliminate the piston rock.
2 I S Attach dial gage (1) in the S measuring bridge (2) with a preload.
3 S Mount measuring bridge (2) onto the contact surface of the crankcase (arrows) and W 0 3 .10-0031-01
Move [Sj measuring bridge (2) from the contact surface of the crankcase over the
cylinder bore.
m
Pull back tracer pin on HQ dial gage (1) when moving measuring bridge.
Measuring pin of S dial gage (1) is pushed back by the piston crown; the reading
obtained is the piston projection.
Additional Information
10
AR03.10-W-7311A Removing, installing piston rings 17.7.95
W03.10-0032-06
m um R e m o v in g , in sta llin g
3 Measure piston ring gap clearance of Insert piston rings in the unworn area BE03.10-N-1001-05B
piston rings (1,2) (above reversal point of 1st piston ring) of
the cylinder wall or cylinder liner and
measure gap clearance.
4 Measure piston ring gap clearance of the Remove garter spring (3.1) from the piston BE03.10-N-1001-05B
piston ring (3) ring.
Insert piston ring in the unworn area
(above reversal point of 1st piston ring) of
the cylinder wall or cylinder liner and
measure gap clearance.
Additional Information
12
AR03.10-W-6111A Inspecting, repairing conrod 21.11.95
1 Conrod
2 Conrod bearing cap
3 Conrod bearing shells
4 Conrod bolt
5 Conrod bush
1 Conrod
3 Conrod bearing shells
5 Conrod bush
6 H j Dial gauge
7 I S Dial gauge holder
S3 Removing
0 Inspecting
2 Inspect conrod (1) for blue discoloration, H I Conrod with blue discoloration (caused
cross scores and notches by bearing damage), with cross scores or
notches must not be reused.
replace conrod.
replace conrod.
replace conrad.
Conrod must not be straightened.
5 Install conrod bearing shells (3), 00 Engines have different conrod bearing Page 17
gage shells in the conrod bearing cap and
conrod. Pay attention to abbreviated part
number on the rear of the conrod bearing
shell halves.
El 001 589 53 21 00
WH5B.30-Z-1006-12A
m WH58.30-Z-1009-12A
6 Calculate axial clearance of conrod bearing Conrod bearing axial play BE03.10-N-1003-01B
m Installing
Additional Information
14
Test data of conrod
Fig. see - -
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 15
Test data of crankshaft
Undersize-0.5 mm 69.495-69.515
Undersize-0.75 mm 69.245-69.265
Undersize-1.0 mm 68.995-69.015
@ Conrod
2nd stage Nm 45 45
3rd stage 90 90
WH58.30-Z-1023-12A Caliper gage with round scale Hahn und Kolb 31 165
Borsigstr. 30
D-70469 Stuttgart
Additional Information
16
AR03.10-W-6111-06A Installing, gaging conrod bearings
Fig. see - -
Undersize-0.25 mm 69.745-69.765
Undersize-0.5 mm 69.495-69.515
Undersize-1.0 mm 68.995-69.015
3rd stage 90 90
1 Measure conrod bearing journal with the micrometer at two points (vertically and at
an angle of about 90) and note measurements. Calculate the average of the conrod
bearing journal diameter from these two measurements.
2 Clean bearing points of the conrod and the conrod bearing cap with a chamois leather.
W 0 3 .10-0033-01
Additional Information
18
3 Insert conrod bearing shells (3) into the conrod and the conrod bearing cap (2).
E Pay attention to marking on conrod bearing shells (3) and code numbers of conrod
relative to conrod bearing cap (2).
Conrod and conrod bearing cap (2) have different conrod bearing shells (3).
Pay attention to abbreviated part number on the rear of the conrod bearing shell
halves.
If the conrod bearings are replaced, install conrod bearing shells (3) of the matching
installation stage; pay attention to measured conrod bearing journal diameter.
Locking lugs (arrows) of the conrod bearing shells should be located in the slots of the
basic bore of the conrod bearing cap (2) and of the conrod.
W 0 3 .10-0002-01
4 Fit conrod bearing cap (2) to fit exactly onto the conrod.
@ Code numbers on conrod and on conrod bearing cap (2) should agree and be
positioned on the one side. The cracked contact surface must not be damaged.
5 0 Lightly oil the thread and contact surface of bolt head of conrod bolt (4) and
tighten with wrench bit.
m Press against conrod bearing cap (2) by hand at the conrod when screwing in the
conrod bolt (4).
Clamp conrod just below the conrod bearing in order to prevent it turning.
6 Set dial gauge and quick calipers with the micrometer to the measurement calculated
beforehand (average) of the conrod bearing journal diameter (preload 5 mm)
7 Measure conrod bearing bore at three points (A, B, C) (vertically and each about 30
away from the separation points, up and down) with dial gauge and quick calipers.
Note measurements.
@ Never bolt conrod bearing cap (2) tight to conrod without the conrod bearing shells
(3) inserted, only position against conrod.
The shank length of the conrod bolts (4) should be measured before re-installing.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 19
AR03.20-W-3000A Replacing front crankshaft radial seal 6.11.95
W 03.20 0032-09
IS) Removing
1 Remove vibration damper (1) Engine 904.905- 907/909- 911 /921 /922 and Page 42
906.910/911/920- 923/940/941
m Inspecting
4 Inspect contact surface at crankshaft for tSIf wear is present, a radial seal with race
scores or traces of wear will be available shortly for repairs.
m Installing
5 Fit guide sleeve (5) onto the crankshaft and Q] Sealing lip of radial seal should point
push radial seal (2) over the guide sleeve (5) toward oil pump at the guide sleeve.
Additional Information
20
6 Press radial seal (2) into the oil pump LlJPress in radial seal dry. parallel to the
axis and evenly around the entire
circumference. Pay attention to installation
po sition a n d setb ack (A ) o f 1-5 m m . Do n o t
damage radial seal when installing.
u 904 589 02 15 00
904 589 00 33 00
y V
Puller
Additional Information
8 ^ ^ Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 21
AR03.20-W-3063A Replacing rear crankshaft radial seal 6.11.95
1 Flywheel
2 Radial seal
3 I S D rift
W03.20-0033-06
m Removing
2 Press out radial seal (2) @ Cover over crankshaft with a cleaning
rag as a protection.
kl Inspecting
3 Inspect contact surface on flywheel for 5 ] if wear is present, a radial seal with race
scores or signs of wear will shortly be available for repairs.
II Installing
4 Fit on radial seal (2) at timing case and [D Press in radial seat dry, parallel to axis
press in and evenly around the entire
circumference. Pay attention to installation
position of radial seal. Do not damage
radial seal when installing.
Additional Information
22
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 23
AR03.20-W-4351 A Removing, installing crankshaft 21.11.95
ENGINE 904.905/906/907/908/909/910/911/921/922/923,906.910/911/920/921/922/923/940/941
1 Crankshaft
2 Top crankshaft bearing shell
3 Bottom crankshaft bearing shell
4 Thrust washer (fit bearing)
5 Main bearing cap
6 Main bearing cap (fit bearing)
7 M ain bearing cap bolt
8 Crankshaft gear
9 Pin
WOB.20-0038-06
m Removing
24
Additional Information
1 Remove engine Engine 904.905-907/921 AR01.10-W-2401A
Engine 904:
the thrust washers of the fit bearing (4) are
installed at the 5th main bearing cap
Engine 906:
the thrust washers of the fit bearing (4) are
installed at the 7th main bearing cap
7 Take off crankshaft bearing shells (3) OD Mark crankshaft bearing shells to the
relative main bearing cap (5,6)
8 Use a tackle to lift crankshaft (1) out of the GD Attach tackle to the crankshaft using
crankcase existing bolts of the belt pulley and of the
flywheel
9 Take out crankshaft bearing shells (2) H Mark crankshaft bearing shells relative
to crankcase
12 Measure main bearing bolts (7) Q j If the shank length (L) was exceeded J. BE01.40-N-1010-02B
13 Install main bearing cap (5) H All main bearing caps are fitted into the
crankcase at the side (off-centered) and
marked with numbers (arrows).
The main bearing caps should be installed
in accordance with the numbers beginning
at the front of the crankcase in ascending
order and must not be mixed up.
Oil main bearing bolts.
001 589 53 21 00
15 Attach crankshaft gear (8) to crankshaft SI Push on crankshaft gear; the marking
flange 1" on the crankshaft gear should be
positioned between the markings 1-1 of
the camshaft gear (10)
16 M o u n t co m od in b e aring s a n d install P a g e 13
21 Replace oil-water heat exchanger @ Only in the case of material abrasion AR18.30-W-6840A
Fig.see - -
Additional Information
26
Test data of crankshaft
BE03.20-N-1016-02B Wall thickness of fit bearing thrust washers Standard mm 3.240-3.300 3.240-3.300
Oversize-0.5 mm 31.500-31.562
4th stage 90 90
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 27
AR03.20-W-4351-01B Determining thickness of fit bearing thrust
washers of crankshaft
BE03.20-N-1016-02B Fit bearing thrust washer wall thickness Standard mm 3.240-3.300 3.240-3.300
4th stage A 90 90
Additional Information
28
363 589 02 21 00
1 Measure fit bearing journal width (A) of crankshafts (1) and assign thrust washers to
match the installation stage measured.
m
The dimensions of the installation stages stated in the table have to be adhered to.
Thrust washers are factory-supplied ready for installation and also in oversizes for
repairs. It is not permitted to carry out any reworking.
2 Oil thrust washers (2) and insert into the grooves on the main bearing cap (fit bearing)
(3).
a
Only thrust washers (2) of the same wall thickness may be installed. Both oil grooves
(arrows) in the thrust washers should point toward the crankshaft webs.
m
Oil main bearing bolts.
The main bearing cap is fitted into the crankcase at the side (off-centered) and marked
with numbers (arrow).
\NQ__ ~~
is s
W03.20-0036-01
5 Attach I S dial gage holder (4) and IS dial gage (5) to the crankcase with a preload. -------- \ e b------ rP r r v r r r
6 Move crankshaft (1) from stop to stop and read off measurement (axial play).
E The axial play must not be greater than the stated figure.
W03.20-0037-01
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 29
AR03.20-W-4355B Measuring and mounting crankshaft 13.6.97
W03.20-0042-09
J Crankshaft A Main bearing journal 0
2 S Drop hardness tester B Fit bearing journal width
3 IS M ic ro m e te r C M a in b e arin g jo u rn a l w id th
4 Main bearing cap D Conrod bearing journal 0
5 Main bearing bolt E Conrod bearing journal width
F Fillet radii o f main, conrod bearing journals
G Ci o w n o f m ain, c o n ro d beat ing jo u rn a ls
H Main bearing inner 0 when installed
1 Crankshaft
7 I S Dial gage
8 IS Dial gage holder
W03.20-0043-05
m Inspecting
30
Additional Information
3 Inspect crankshaft flange at front for wear S3 If wear is present, a radial seal with race
will shortly be available for repairs
Replace crankshaft.
6 Measure radial runout of crankshaft (1) S3 Measured at middle main bearing BE03.20-N-1011-02B
journal, mounted on outer main bearing
journals.
IS 001 589 53 21 00
IS 363 589 02 21 00
7 Measure main, conrod bearing journals Measure main bearing journal 0 (A) at two BE03.20-N-1001-02B
points (offset approx. 90) with the
micrometer.
SS Micrometer WH 58.30-Z-1006-12A
[3 If d a m a g e a n d w e a r p re sen t J,
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 31
Engine 906 B E03.20-N-1022-02B
Permissible imbalance of crankshaft (with
p in fo r fix in g fly w h e e l b u t w ith o u t
flywheel), mounted on main bearings two
and six.
Mounting in bearings
IS 001 589 53 21 00
I S Micrometer WH58.30-Z-1013-12A
Additional Information
32
Test data of crankshaft
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 33
Test data or crankshaft
Additional Information
34
Test data of crankshaft
Undersize-0.1 mm 85.890-85.910
Undersize-0.25 mm 85.740-85.760
Undersize-0.5 mm 85.490-85.510
Undersize-1.0 mm 84.990-85.010
Undersize-0.3 mm 31.300-31.362
Undersize-0.5 mm 31.500-31.562
Undersize-0.1 mm 69.895-69.915
Undersize-0.25 mm 69.745-69.765
Undersize-0.5 mm 69.495-69.515
Undersize-0.75 mm 69.245-69.265
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 35
Test data of crankshaft
4th stage 90 90
W H S S .3 0 -Z -1 0 0 6 -1 2 A M ic ro m e te r 50-75 m m
Additional Information
36
AR03.20-W-43 55-01B Positioning crankshaft in mounts radially
Undersize-0.1 mm 85.890-85.910
Undersize-0.25 mm 85.740-85.760
Undersize-0.5 mm 85.490-85.510
Undersize-0.75 mm 85.240-85.260
Undersize-1.0 mm 84.990-85.010
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 37
S Crankcase, timing case cover, end cover
2nd stage Nm 80 80
2 Measure main bearing journal 0 (D) at two points (offset approx. 90) with the I S
m ic ro m e te r.
a
The figures stated in the table should be adhered to. If one of the measurements
obtained is beyond the tolerance, machine crankshaft.
Additional Information
38
3 Clean bearing points in the crankcase and main bearing cap with a chamois leather.
4 Insert crankshaft bearing shells (2) into the crankcase in the order marked.
e
The locking lugs (a r r o w ) o f th e cra n k sh a ft b e arin g shells (2) should b e lo cated in th e
slots of the crankcase basic bores. Oil drillings in the crankshaft bearing shell (2) and
crankcase should be aligned.
E
All the main bearing caps are fitted into the crankcase at the side (off-centered) and
marked with numbers (arrows).
They have to be installed in accordance with numbers beginning at the front of the
crankcase in ascending order and must not be mixed up.
Oil main bearing bolts (6).
W03.20-0004-01
7 Set dial gage and quick calipers with the micrometer to the nominal dimension of the
main bearing journal (preload 5 mm).
8 Measure crankshaft bearing bores in the crankwse at three points (A, B.C) (vertically
and each approx. 30 away from the separation points) with the dial gage and quick
calipers.
E
The figures stated In the table should be adhered to. If one of the readings obtained
(A, B, C) is not within the tolerance, replace main bearing shells in accordance with the
main bearing journals measured.
Main bearing shells are factory-supplied ready for installation and also in oversizes for W03.20-0005-01
repairs. It Is not permitted to carry out any reworking.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 39
AR03.20-W-4803A Removing, installing crankshaft sprocket 28.8.95
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921/922/923
ENGINE 904.908/923 in MODEL 668, 670
ENGINE 906.940/941 in MODEL 957
1 Timing case
2 Crankshaft sprocket
3 Camshaft sprocket
W 03.20-0007-06
3 Pull crankshaft sprocket (2) off the cranks H I Installing: push crankshaft sprocket
haft over the dowel pin in the crankshaft.
The marking "1" on the crankshaft sproc
ket should be positioned between the mar
king 1-1" (arrow) on the camshaft sproc
ket.
4 Install in th e re ve rse o rd er
Additional Information
40
AR03.20-W-4841 A Removing, installing drive gear for oil pump on crankshaft 28.8.95
W 03.20-0006-10
Em u Removing, installing
S Danger! Risk of injury to eyes and skin from Wear protective gloves, protective clothing Page 41
h a n d lin g h o t o r g lo w in g objects and, if necessary, eye p ro tectio n .
2 Pull drive gear (1) off the crankshaft (2) Heat drive gear to about 200 C.
CD Installing: heat new drive gear to
about 200 C and press onto the crankshaft.
Pay attention to installation position of
chamfer (arrow).
AS00.00-Z-0002-01A Risk of injury to skin and eyes from Wear heat resistant gloves, protective Danger!
handling hot or glowing objects clothing and protective goggles if
necessary
Additional Information
< ^8* Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 41
AR03.30-W-1600A Removing, installing belt pulley/vibration damper 17.7.95
W 0 3 .30-0017-06
Modification notes
7.7.95 Use of new bolts for attaching vibration damper Step 6 Page 42
2 Detach cover at timing case 0 Bolt of end cover to timing case BA01.60-N-1002-01A
3 Install cranking and blocking device for U] Block cranking and blocking device by P ag e 44
engine at timing case inserting the pin.
904 589 04 63 00
Additional Information
42
Belt pulley / vibration damper
E3 Timing case
3rd stage 90 90
3rd stage 90 90
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 43
AR03.30-W-1600-03A Attaching, detaching cranking/blocking
device for engine
@ Timing case
3 Attach E l cranking and blocking device (2) tightto flywheel housing with bolts (4).
E Cranking and blocking device (2) can be blocked by inserting the pin (3).
Cranking and blocking device (2) must be removed before starting the engine.
Additional Information
44
AR03.30-W-8002A Removing, installing flywheel 18.7.95
W03.30-0018-06
Operation no. of operation texts or standard texts and flat rates
F, T, S 03-8001- Flywheel
8042
mi [m Removing, installing
Engine 904.908/923
2 Pull crank angle position sensor (B15) Do not damage crank angle position
approx. 8 mm out of timing case sensor with the ring gear when pulling off
the flywheel (1).
E Installation: press crank angle position
sensor into the housing as far as the stop.
3 Attach cranking and blocking device (3) to E Block cranking and blocking device by Page 44
the timing case inserting the pin.
904 589 04 63 00
4 Unscrew flywheel bolts (2) CD Installation: oil flywheel bolt lightly
and screw tight.
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 Additional Information 45
El 904 589 0010 00
7 Remove flywheel (1) over the centering [2 If flywheel is tight, screw two bolts (M8)
drifts (4) into opposite threaded holes and pull off
flywheel.
@ Inspecting
8 Measure flywheel bolts (2) E If the maximum shank length (L) was BE03.30-N-1010-03B
exceeded 4
9 Inspect clutch surface on flywheel (1) E If scorches, scores or cracks are present
in the clutch surface J
10 Inspect flywheel flange for signs of wear E If wear is present, a radial seal with race
and traces of hollowing caused by radial will soon be available for repairs.
seal
Number Designation Engine 904 with Engine 904 with Engine 904.908/
SAA 505.009/06 SAA 505.009/03 923
B E 0 3 .3 0 - M - 1 0 0 8 - 0 2 Q F ly w h e e l - m in im u m w id th mm 55 55 55
between friction surface and
Fig. see - - -
mounting flange for repairs
(E)
Additional Information
46
Test data of flywheel
0 T im in g case
Repair products
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 47
AR03.30-W-8022A Inspecting, machining flywheel 21.11.95
ENGINE 904.905 /906 /907 /909 /910/911 /921 /922,906.910/911 /920 /921 /922 /923
ENGINE 904.903/923 in MODEL $38. 670
1.2K
1.3-
'7 7 /A
D A B C D A B C D A
H Removing
m Inspecting
2 Clean flywheel (1) and inspect clutch EL) If a fault exists, the clutch surface
surface (friction surface) for scorches, (friction surface) has to be machined by
scores and cracks and flatness using a grinding or precision-turning.
knife-edge straightedge (3)
m WH58.30-Z-1025-12A
replace flywheel
Machining
Additional Information
48
Flywheel 0 for mounting starter ring gear BE03.30-N-1002-03B
(B)
m Installing
Fig. see - - -
Fig. see - - -
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 49
Test data of flywheel
Fig.see - -
Fig. see - -
B E 0 3 .3 0 -N 100 S 03 3 F ly w h e e l m in im u m w id th mm 55 55
between friction surface and
Fig. see - -
mounting flange for repairs
(E)
Additional Information
50
AR03.30-W-8312A Replacing ring gear of flywheel 17.7.95
1
A Hole for mounting clutch pressure
plate (M 10X1.5) -L*
B Flywheel 0 for mounting starter ring
gear f
2.2
1
2.3 -A
W03.30-0020-06
Replacing
Danger! Risk of injury to eyes and skin from W ear protective gloves, protective clothing Page 41
handling hot or glowing objects and, if necessary, eye protection.
6 Heat new starter ring gear (1) E Temperature is reached once the ring BE03.30-N-1005-04B
gear has a bright yellow annealing color
7 Press starter ring gear (1) onto the flywheel E The permissible radial runout of the BE03.30-N-1003-04B
(2) as far as the contact surface pressed-on starter ring gear must not be
exceeded
8.1 Drill holes (A) for mounting the clutch Engine 906 with SAA 505.009/05/14
pressure plate in the ring gear (l)a n d tap
thread (M10X1.5)
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 51
Test data of flywheel
Number Designation Engine 904 with Engine 904 with Engine 904.908/
SAA 505.009/06 SAA 505.009/03 923
Additional Information
52
AR03.30-W-8401 A Removing, installing guide bearing in flywheel 21.11.95
HH Removing, installing
Engine 904.908/923
2 Detach cover at timing case 0 Bolt of end cover to timing case BA01.60-N-1002-01A
3 Attach cranking and blocking device (4) EE Block cranking and blocking device by Page 44
inserting the pin.
E 904 589 04 63 00
E 904 589001000
5 Measure shank length (L) of flywheel bolts If maximum shank length is exceeded | BE03.30-N-1010-03B
(1)
7 Remove guide bearing (2) Place bases, e.g. copper plates, below
the contact points of the countersupport to
avoid damaging the flywheel (3).
n 000 589 33 33 00
Number Designation Engine 904 with Engine 904 with Engine 904.908/
SAA 505.009/06 SAA 505.009/03 923
S Timing case
3rd stage *4 90 90
Additional Information
54
"\ r S
Repair products
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 55
AR05.00-W-1500A Checking valve lift 28.8.95
A V a lve clearance
B Valve lift
W05.00 1001-06
M o d ific a tio n no tes
m Removing
s 904 589 04 63 00
s Checking
6 Mount dial gage holder (4) with dial gage E E Mount dial gage with a preload of
(5) on the valve spring retainer of the valve approx. 15 mm so that the travel is
spring (6) of the exhaust valve or valve adequate for the valve lift (B).
bridge (7) of the inlet valve
na 001 589 53 21 00
56
Additional Information
m 363 58902 2100
8 Crank engine with cranking device in HI The maximum valve lift is indicated on
direction of rotation of engine and read the dial gage before the pointer moves in
off valve lift(B) the opposite direciton. The valves (2) are
fully open at this point.
9 Compare measurement obtained with CD if the valve lift (B) measured is less than BEO..-N-12-01B
specification specification, inspect cams of camshaft for
wear, if necessary 1
m Installing
HI 904 589 04 63 00
13 Install cover at timing case @ Bolt of end cover to timing case BA01.60-N-1002-01A
Timing case
'S
\\(o
]
^ ! r )
V 904 589 04 63 00 J
Cranking device
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 57
AR05.00-W-5521 A Removing, installing rocker arm assembly 17.7.95
W 05.00-0015-06
Modification notes
2 Remove clamping piece (3) and rocker arm Inspect rocker arm assembly for wear, if ne
assembly (4) cessary I
Additional Information
58
0 Locking nut at adjusting screw of valve BA05.00-N-1003-01A
bridge
4 Measure projection (A) of guide bolts (7) If dimensional differences exist j, BE05.30-N-1003-04B
from cylinder head
Modification notes
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 59
a
Carry out setting of valve bridges (3) only when engine is cold or thoroughly warmed
through. W ait at least 30 minutes after switching off the engine.
1 Clamp valve bridges (3) in a vise, slacken locking nut (1) and unscrew adjusting screw (2)
about 3 turns.
2 Install valve bridges (3) over the guide bolts on the cylinder head.
3 Press valve bridge (3) down. Valve bridge (3) should be making contact with valve stem
(arrow A).
4 With valve bridge (3) pressed down, screw in adjusting screw (2) by hand until the
adjusting screw (2) makes slight contact with the valve stem (arrow B).
a
Valve bridge (3) must not move up.
7 Clamp valve bridges (3) in a vise, tighten adjusting screw (2) and locking nut (1) to
specified torque.
8 Install valve bridges (3) over the guide bolt on the cylinder head.
Additional Information
60
ARO5,00-W-5521C Removing, installing rocker arm assembly 30.9.97
W0S.Q0-0O16-06
MM Removing, installing
2 Remove clamping piece (3) and rocker arm Inspect rocker arm assembly for wear, if ne
assembly (4) cessary \
4 Take off valve bridges (5) at the inlet valves Inspect valve bridges for wear, if necessary
I
replace valve bridges.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 61
S Engine timing, general
Additional Information
62
AR05.00-W-5541 A Disassembling, assembling rocker arm assembly 17.7.95
1 C irri ip 8 Rocker a rm s h a ft
2 Rocker arm bracket (at front on outside) 9 Bolts
3 Rocker arm bracket (on inside) 10 Clamping piece
4 Rocker arm bracket (at rear on outside) 11 Washer
S Rocker a rm (in le t)
6 Rocker arm (exhaust) A Distance 122 mm
7 Springs B Distance 110 mm
0 Removing
0 Disassembling
3 Take rocker arm brackets (2,3,4), rocker Inspect parts of rocker arm assembly for
arms (5, 6). washers (11) and sorinos (7) off wear, if necessary 1
the rocker arm shaft (8)
replace parts.
0 Assembling
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 63
4 Install cirdip (1) on one side of the rocker EL) Pay attention to installation position of
arm shaft (8), assemble rocker arm outer rocker arm brackets (2,4) and of
assem bly in t h e re ve rse o rd e r an d secure ro ck e r a rm b rack ets (3).
with the cirdip (1) Fix rocker arm brackets (2,3,4) in place
with the bolts (9) and the clamping pieces
(10).
P a y a tte n tio n t o d ista n c e o f holes o f o u te r
rocker arm brackets (2,4) to the inner
rocker arm bracket (3).
Distance "A " 122 mm
D ista n ce " D " 110 m m
m Installing
B E 0 S .3 0 -N 10 01-01B R o c k e r a r m b e a r in g b u s h i n n e r 0 mm 2 2 .0 0 0 - 2 2 . 0 2 1 2 2 .0 0 0 -2 2 .0 2 1
when installed
Additional Information
64
AR05.30-W-3511A Removing, installing valves 21.11.95
1 Valve collet
2 Valve spring retainer
3 Inlet valve spring
4 Exhaust valve spring
5 Cylinder head
6 Inlet valve
7 Exhaust valve
8 H I Valve lifter with adapter piece
9 Valve stem seal
W 0 5 .3 0 -M 5 7 -0 6
5 Cylinder head
6 Inlet valve
7 Exhaust valve
10 (Ml Dial gage
77 E l Dial gage holder
W 05.30-0064-06
H is Removing, installing
1 Remove cylinder head (5) Engine 904.905- 907/909- 911 /921/922 and AR01.30-W-5800A
906.910/911/920- 923/940/941
3.2 Measure amount by which valve stands Engine 904.909- 911/922 and Page 71
back (B) to cylinder head, and permissible 906.910/911/920- 923/940/941
d iffe re n c e b e tw e e n b o th in le t v a lv e tem c
[H If th e m ea su rem en ts o b ta in e d are n o t
within the permissible tolerance i
5 Attach valve lifter (8) to the cylinder head 23 Screw stud bolt of valve lifter Into a
(5) free threaded hole in the cylinder head.
Attach adapter piece to the valve lifter.
6 Press down valve spring retainer (2) with ID Counterhold valve at the valve disk.
valve lifter (8) and take off collets (1) with
the magnetic pin
9 Pull off valve stem seals (9) E Installation: replace valve stem seals. Page 78
66
Additional Information
10 Inspect valve seat rings Measure valve seat width at all valve seat BE05.30-N-1007-03B
rings.
BE05.30-N-1003-02B
BE05.30-N-1006-02B
13 Inspect concentricity and dimensional Concentricity of valve seat to valve stem BE05.30-N-1011-01B
tolerance of valves (6,7)
SS Micrometer WH58.30-Z-1005-12A
B C 0 3 .3 0 - N - 1 0 0 3 - 0 1 B V o lv c s ca t a n g le (A ) In let S 20 20 20
Exhaust 4 45 45 45
B E05.30-N-1005-01B Valve seat width at valve disk (F) Inlet mm 3.3-4.3 3.3-4.3 3.3-4.3
BE05.30-N-1008-01B Inlet valve seat surface machining Dim. G mm 31.0 31.0 31.0
dimension (H) related to valve seat
Dim. H mm 2.7-3.1 2.7-3.1 2.7-3.1
surface 0 (G)
B E05.30-N-1009-01B Exhaust valve seat surface machining Dim. G mm 36.0 36.0 36.0
dim ensio n (H ) re la te d to v a lv e sc a t
Dim. H mm 2.5-3.2 2.5-3.2 2.S-3.2
surface 0 (G)
BE05.30-N-1010-01B Hardness at valve stem end Inlet HRC 54-60 54-60 54-60
Additional Information
68
Test data of valve guides
Exhaust mm 0.060-0.037
B E05.30-N-1007-03B Valve seat width at valve seat ring (F) Inlet mm 1.5-2.5 1.5-2.5
Fig. see - -
001 589 53 21 00
Dial gage
343 589 00 40 00
D ia l g a g a h o ld e r
DD
Valve disk (3) should be making contact with valve seat.
2 Mount m dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move S dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
If th e rea d in g o h ta in e d (A ) is n o t w ith in th e perm issible to le ra n ce , inspect v a lv e seat
ring orthe valve disk.
Additional Information
70
AR05.30-W-4100-01C Measuring amount by which valve stands
back to cylinder head
Test d a ta o f v a lv e s
a r
m
Valve disk (3) should be making contact with valve seat.
2 Mount H] dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move I S dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
If the reading obtained (A) is not within the permissible tolerance, inspect valve seat
ring or the valve disk.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 71
5 Attach I S dial gage (1) to I S the dial
gage holder (4) and mount on the top
contact surface of the cylinder head.
m
Permissible difference (C) between
both inlet valve stem ends (5) must not
be exceeded. W05.30-0058-05
Additional Information
72
AR05.30-W-3731 A Inspecting, removing, installing valve guides 4.12.95
W 05.30-0003-06
W 05.30-0004.09
IE Removing
4 Take valve guides (1 ) out of the cylinder E Progressive drift 103 589 03 15 00
head (2) from the combustion side
m Installing
5 Measure bore of valve guides dimension E If the measurements differ from the BE05.30-N-1002-02B
(A) in cylinder head (2) test data 4
6 Ream bore of valve guides dimension (A) in T u rn reamer only in clockwise direction. BE05.30-N-1002-02B
cylinder head (2) to the next larger oversize
Danger! Risk of injury from handling liquid Wear heat-protective gloves, protective Page 77
nitrogen or from contact with severely clothing and full eye protection.
supercooled objects. Ensure adequate ventilation.
Risk of suffocation from inhaling nitrogen
gas.
7 Place valve guide (1) into supercooling box HD Supercooling box 346 589 00 63 00
and pour in liquid nitrogen E Supercool valve guide for approx.
20 lo 30 minutes.
8 Use pliers to remove valve guide (1) from E Support washers of the valve guide
the supercooling box and press into the should be removed.
heated cylinder head with the drift and the
spacer sleeve (6)
9 Widen bore of valve stems by reaming E Reamer (adjustable 07.5 - 8.0 mm) WH58.30-Z-1014-12A
E Ream to 07.95 mm
T u rn reamer only In clockwise direction.
74
Additional Information
10 Widen bore of valve guide to dimension (B) BE05.30-N-1003-02B
by reaming
11 Clean valve guide (1) with cleaning brush I S Valve seat turning kit 366 589 00 6900
Fig. see - -
Fig. see - -
Fig. see - -
BE05.30-N-1005-02B Valve guide overlap in cylinder head mm 0.010-0.046 0.010-0.046
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 75
Test data of valve guides
Fig. see -
Fig. see -
Fig. see -
Additional Information
76
Commercially available tools (see Workshop Equipment Manual)
AS00.00-Z-0003-01A Risk of injury from handling liquid Wear insulated gloves, protective A Danger!
nitrogen, or from contact with supercooled clothing and full protective goggles.
objects. Risk of suffocation from inhaling Provide for sufficient ventilation.
nitrogen gas
Possible dangers - Do not remove ice formed on containers with open flame or
glowing objects.
Injury hazard - When filling or pouring liquid nitrogen avoid spilling. Fill
Contact with liquid nitrogen or supercooled objects causes containers only up to full mark.
frostbite to skin similar to burns and severe injury to the eyes. - Wear protective clothing, full protective goggles, insulated
Suffocation hazard gloves (e.g.: leather, Kevlar).
Liquid nitrogen evaporates to produce nitrogen gas which has a - Store liquid nitrogen only in containers intended for this
suffocating effect at high concentration without any noticeable purpose.
warning.
First-aid measures
Rules of behavior/protective measures Do not rub affected areas of skin, rinse with large quantities of
- Eating, drinking, smoking and stowage of foodstuffs lukewarm water and cover with sterile dressings.
prohibited in work room. Remove contaminated clothing immediately.
- Provide for sufficient ventilation of work room, never use Move unconscious persons to fresh air immediately, perform
liquid nitrogen in area of assembly pits. artificial respiration if necessary.
- Handle containers, apparatus and fittings carefully, dry well Consult physician immediately.
before filling, secure against accidents.
Additional Information
Engines O M904 LA, 906 LA (mod. des. 904.9,906.9), F4 77
AR05.30-W-351 OA Replacing valve stem seals 11.10.95
ENGINE 904.905/906/907/908 /909 /910 /911 /921 /922, 906.910 /911 /920 /921 /922 /923 /940/941
iS j Spacer sleeve
Valve stem seal
S3 Sleeve
Supporting washer
Inlet valve
Exhaust valve
Valve guide
W05.30-0056-02
3 Removing
m Installing
6 Push sleeve (3) over the valve stem until it n 346 589 01 61 00
makes contact with the valve guide
8 Install new valve stem seal (2) with spacer @ Press valve stem seal onto the valve
sleeve (1) guide as far as the stop and inspect that it is
tightly seated at the valve guide collar.
Additional Information
78
904 589 08 63 00
Sleeve
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 79
AR05.30-W-3831A Replacing valve seat rings 18.7.95
W 05.30-0005-06
m m Removing, installing
Additional Information
80
5 Measure valve seat ring bore diameter, size 0D It is important to ensure overlap bet
(B), in cylinder head ween valve seat ring, size (A), and basic bo
re, size (B).
If the sizes differ from the specifications,
the basic bores must be machined to the
next oversize of the valve seat ring diame
ter (A).
In le t v a lv e s ea t ring o u te r 0 (A ) BE05.30-N-1001-03B
I S Micrometer WH58.30-Z-1005-12A
I S Micrometer WH58.30-Z-1007-12A
Danger! Risk of injury from handling liquid W ear heat-protective gloves, protective Page 77
nitrogen or from contact with severely clothing and full eye protection.
supercooled objects. Ensure adequate ventilation.
Risk of suffocation from inhaling nitrogen
gas.
7 Insert valve seat rings in cooling box and GO Supercool valve seat rings for about 20
pour in liquid nitrogen to 30 minutes
A Danger! Risk of injury to eyes and skin from Wear protective gloves, protective clothing Page 41
handling hot or glowing objects and, if necessary, eye protection.
Exhaust mm 0.060-0.097
Additional Information
82
Test data of valve seat rings
BE05.30-N-1001-03B Inlet valve seat ring outer 0 (A) Standard mm 35.07-35.08 35.07-35.08
Fig. see - -
B E05.30-N-1002-038 Exhaust valve seat ring outer 0 (A) Standard mm 40.07-40.08 40.07-40.08
Fig. see - -
Fig. see - -
BE05.30-N-1 Q04-03B Valve seat rings -overlaD in cylinder Inlet mm 0.045-0.080 0.045-0.080
head
Exhaust mm 0.045-0.080 0.045-0.080
Fig. see - -
Fig. see - -
Fig.see - -
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 83
JE
346 589 00 63 00 366 589 006900
WH58.30-Z-1025-05A Valve seat ring turning tool Model RD52 220 00100
Hunger
D-81309 Mnchen 70
AR05.30-W-3831-01 A R em o v in g v a lv e s e a l n n gs
a r
000 589 29 33 00
Internal extractor
Additional Information
84
1 Insert pilot (2) (8 mm 0 ) into the valve guide (1) until the stop (arrow) of the tensioning
pliers (3) makes contact with the valve guide (1). Push clamping pliers (3) down with
screwdriver, if necessary. Screw tight with the drift inserted into the top and bottom of
the pilot (2).
W 05.30-0007.01
m
It must be possible to move the tool slide (8) relatively easily back and forward with the
quick-adjuster (9).
5 Insert turning tool (5) over the pilot (2) until the stop pin on the pilot (2) or the cutting
tool (7) touches the cylinder head.
The cutting tool must not strike the cylinder head otherwise the carbide metal tip will
he d am ag ed .
W05.30 0009 01
6 Turn quick adjustment (8) until the cutting tool (7) makes
contact with the pilot (2) or is positioned ahead of the valve
seat ring, but not touching.
7 Hold turning tool (5) tight, slacken clamping screw (12) of the
stop pin (10), carefully lower turning tool (5) until the blade
of the cutting tool (7) is about 1 mm above the inner edge of
the valve seat ring (11), size (X). Press stop pin against pilot
(2), tighten clamping screw(12).
ffl
It must now be possible to just as easily turn the turning tool
as before.
9 Hold knurled plate (15) for the infeed control tight and turn
hand crank (16) clockwise. This usually produces an irregular
stock removal.
0
Check d istance (X ) a b o u t 1 m m a t v a lv e s ea t ring (11).
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 85
10 Turn hand crank (16) clockwise and at the same time hdld the knurled plate (15) tight.
As the turning resistance increases, briefly release knurled plate. Depth of annular
groove, size Y, about 2 to 3 mm.
m
Do not remove too large a chip. It must be possible to easily rotate the turning tool,
which is achieved by briefly releasing the knurled plate.
12 Attach 03 internal extractor (17) for inlet and exhaust valve seat ring (8) in the annular
groove and remove valve seat ring using I S countersupport (18).
Place copper plates (arrows) below the contact surfaces of the 03 countersupport so as
not to damage the cylinder head surface.
BE05.30-N-1001-03B Inlet valve seat ring outer 0 (A) Standard mm 35.07-35.08 35.07-35.08
Fig. see - -
Fig.see - -
Fig. see - -
Additional Information
86
Test data of valve seat rings
Exhaust "X 45 45
Fig. see - -
BE05.30-N-1007-03B Valve seat width at valve seat ring (F) Inlet mm 1.5-2.5 1.5-2.5
Fig. see - -
Fig. see - -
Fig. see - -
Fig. see - -
Fig. see - -
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 87
Commercially available tools (see Workshop Equipment Manual)
3 Moisten pilot (2) with oil, insert turnin tool (4) over the pilot until the stop pin (5) on
the pilot or the cutting tool (16) touches the cylinder head.
T h e c u ttin g to o l m ust M u ls h ike th e cy lin d e r h e a d o th e rw is e th e ca rb id e m e ta l t ip W ill
be d a m a g e d .
4 Turn quick adjustment (5) until the cutting tool (16) moves horizontally beyond the
hole, then push the turning tool (4) down until the cutting tool makes contact with the
cylinder head.
Additional Information
88
5 Hold turning tool (4) tight, slacken clamping screw (6) of the
stop pin (7), carefully lower turning tool. Tighten clamping
screw.
6 Turn the knurled plate (8) in order to set the height of the
cutting tool (16) so that it is still just free.
m
For this step, the working depth (X) should be set between
setting ring (11) and pendulum guide.
8 Calculating the setting "G ": basic bore dimension B" and
pilot diameter dimension F" divided by 2.
Example:
Dimension B = 35 mm (basic bore)
Dimension F = 14.55 mm (pilot diameter)
Dimension G = B + F
2
10 Slacken quick adjustment (5), raise turning tool slightly and position B micrometer
against pilot. Use the quick adjustment to set the cutting tool (16) to the setting G".
Screw quick adjustment tight.
m
It is good practice to set the cutting tool 0.1 mm less in diameter for the first cut.
11 Slacken clamping screw (12). Screw in horizontal stop screw (13) until it touches the
housing and screw clamping screw (12) tight.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 89
12 Fix knurled screw (8) in place with hexagon bolt.
13 Turn out the basic bore for the valve seat ring by turning the hand crank (14) and at the
same time holding tight the top knurled plate (11) for the vertical infeed until the
setting ring (arrow) is making contact with the steady rest bearing (9).
ffl
Re-set cutting tool (16) as often as necessary until the calculated setting "G " is
achieved. After this, once again turn without any cutting infeed.
14 Raise turning tool (4) slightly. Slacken quick adjustment (5) and move back cutting tool
(16).
15 Face the end surface at the bottom by turning the hand crank (14) and at the same time
holding tightthe bottom knurled plate (15) forthe horizontal infeed until the stop
screw (13) makes contact with the turning tool (4).
17 Gage the basic bores (B) for the valve seat rings in the cylinder head with the 13 quick
calipers for internal measurement and I S dial gage.
s
Overlap between valve seat ring dimension (A) and basic bore dimension (B) should be
assured.
Additional Information
90
AR05.30-W-4511A Machining valve seat rings 21.11.95
W 0 5 .30-0062-06
W 05.30-006S-06
IE! Removing
1 Remove cylinder head Engine 904.905- 907/909- 911 /921/922 and AR01.30-W-5800A
906.910/911/920-923/940/941
US Removal
. Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 29
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. W ear protective clothing when handling
fuel.
5 Attach adapter (2) and impact extractor (3) Ill 355 589 01 63 00
to the female thread (M 8) of the nozzle
holder combination (1)
34
Additional Information
3 Clamp cylinder head (3) on valve removal I S Valve removal tool WH58.30-Z-1001-14A
tool (5)
Inspecting
4.2 Measure amount by which valve stands Engine 904.909- 911/922 and Page 8
back and permissible difference to cylinder 906.910/911 /920- 923/940/941
head (3)
5 Pull valves (1, 2) out of the cylinder hfead (3) B Mark valves.
6 Inspect valve seat rings (6) Q3 If valve seats are only slightly worn, it is
possible to machine both inlet or exhaust
valve rings without replacing the valve seat
rings.
Amount by which valve stands back at all
valves and permissible difference between
b o th in let v a lv e stem en ds m ust n o t b e
exceeded.
If wear is present |
4
Additional Information
Machining
8 Machine valve seat ring (6) in cylinder head Engine 904.909- 9111922 and Page 10
(3) 906.910/911/920-923/940/941: both inlet
valve seat ringsshould be machined to the
same depth. The permissible difference
between both valve stem ends must not be
exceeded.
Inspecting
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9.906.9). F4 5
Test data o f valves
B E 0 5 .3 0 -N -1 0 0 9 -0 2 B V a lv e se a t to v a lv e g u id e - m m 0.04 0.04
concentricity
T est d a ta o f v a lu e g u id es
Exhaust mm 0.060-0.097
Additional Information
6
Test data of valve seat rings
Fig. see - -
Fig. see - -
BE0S.30-N-1011-03B Inlet valve seat surface at valve seat Dim. G mm 31.0 31.0
ring machining dimension (H)
Dim. H mm 4.2-4.4 4.2-4.4
re la te d to v a lv e s e a t surface 0 (G )
S 3
^ 343 589004000 J
Dial gage Dial gage holder Drift Dial gage holder
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 7
AR05.30-W-4100-01A Measuring amount by which valve stands
back to cylinder head
m
Valve disk (3) should be making contact with valve seat.
2 Mount [S I dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move S I dial gage (1) sufficiently until the tracer pinis touching the valve disk (3).
ffl W05.30-0060-01
If th e re a d in g o b ta in e d (A ) is n o t w ith in th e p erm issible to le ra n c e , inspect v a lv e seat
ring or the valve disk.
Additional Information
8
f \
343 589004000 J
m
Valve disk (3) should be making contact with valve seat.
2 Mount IS ] dial gage (1) with a preload onto the plane face of the cylinder head.
4 Move IS ] dial gage (1) sufficiently until the tracer pin is touching the valve disk (3).
m W05.30-0060-01
If the reading obtained (A) is not within the permissible tolerance, inspect valve seat
ring or the valve disk.
m
Permissible difference (C) between
both inlet valve stem ends (5) must not
be exceeded.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 9
AR05.30-W-4532-01A Machining valve seat rings with turning
tool
ng. see - -
Fig. see - -
BE05.30-N-1011-03B Inlet valve seat surface at valve seat Dim. G mm 31,0 31.0
ring machining dimension (H)
Dim. H mm 4 .2 - 4 4 4 .2 - 4 4
related to valve seat surface 0 (G)
1 Insert pilot (2) (8 mm 0 ) into the valve guide (1) until the stop (arrow) of the tensioning
damp (3) is touching the valve guide (1); push tensioning damp (3) down with a
screwdriver, if necessary. Tighten with the drift inserted at the top and bottom of the
pilot (2).
Additional Information
10
2 Attach turning head (4) to the turning tool (5), screw in bothhexagon socket screws (6)
loosely, align turning head (4) so that the distance between the rack and the opposite
side is about 0.5 to 0.8 mm. Then, tighten both hexagon socket screws (6).
Inlet valve - * turning head D2/20
Exhaust valve--turning head D2/45
m
It must be possible to move the tool slide (8) relatively easily back and forward with the
quick-adjuster (9).
5 Insert turning tool (5) over the pilot (2) until either the stop pin (10) on the pilot (2) or
liie cu ttin g lu u l (7) is to uch in g the c y lin d e i head .
Cutting tool (7) must not strike the cylinder head otherwise the carbide metal tip will
be damaged.
7 Hold turninq tool (5) tight, slacken clamping screw (17) of the
stop pin (10), carefully lower turning tool (5) until the blade
of the cutting tool (7) is touching the middle of the valve seat
ring (11). Press stop pin (10) against pilot (2), tighten dam
ping screw (12).
DD
It must be possible now to rotate the turning tool (5) just as
easily as before.
10 Raise turning tool (5) and position cutting tool (7) next to the
inner valve seat edge by turning the quick-adjuster (9).
m W 05.30-0029-12
Do not set any cut feed.
11 Hold knurled plate (15) for infeed control tight and turn
hand crank (16) clockwise. This usually produces an irregular
stock removal.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 11
12 After this turning operation, move the cutting tool (7) back again next to the inner
valve seat edge with the quick-adjuster (9).
13 Slacken locking screw (17) and turn the knurled plate (18) anti-clockwise about 1/2 to
1 g ra d u a tio n (a rro w ). T ig h te n lo c k in g scre w (17).
m
1 graduation = 0.1 mm infeed
14 Hold the knurled plate (15) for the infeed control tight and turn hand crank (18) clock
wise. Turn the outside diameter of the valve seat with the tip of the cutting tool (7).
m
A stock removal should be performed as often as necessary
(steps 13 and 14) until the valve seat is smooth and free of
chatter marks and the valve seat width (F) and valve seat
diameter (G) are achieved; see test data.
Engine 904.909-911/922 and 906.910/911: both inlet valve
s e a t ring s sh o u ld be m a c h in e d t o t h e s a m e d e p th . The
permissible difference between both inlet valve stem ends
must not be exceeded.
15.1 Raise turning tool (5) and slacken clamping screw (12) of the stop pin (10).
15.2 Turn quick adjustment (9) so that the cutting tool (7) is touching the outer valve seat
edge.
15.3 Press stop pin (10) down until it is touching the pilot. Tighten clamping screw (12).
7-
11 Hi
W OS.30-0091-02
Additional Information
12
15.4 Sla ck e n lo c k in g s c re w (17) a n d tu rn th e k n u rle d p la te (18) a b o u t 1/2 g ra d u a tio n
(arrow) in an anti-clockwise direction. Tighten locking screw again.
15.5 Hold crank arms with both hands and move turning tool (5) down in stages with slight
pressure around the pilot.
15.6 Repeat steps 15.4 and 15.5 until the required valve seat width is achieved; see test data
a
After that, once again turn without any chip feed.
m
Do not remove pilot (2).
Additional Information
Engines O M904 LA, 906 LA (mod. des. 904.9,906.9), F4 13
Commercially available tools (see workshop Equipment Manual)
1 Insert E damping ring (1) over the installed pilot of the valve turning tool and clamp
tight.
3 Position tracer pin of the tester (2) on the middle of the valve seat with a preload.
m
Slowly turn tester around the pilot and, in so doing, check the radial runout of the
valve seat; see test data.
4 Take off 3 tester (2), clamping ring (1) and pilot. W 05.30-0063-01
Additional Information
14
AR05.30-W-4202A Grinding valves 18.7.95
1 Valve
2 IH V alve g rin d in g m achine
W05.30-0061-06
Grinding
3 Set valve seat grinding angle on valve Valve seat angle (A) BE05.30-N-1003-01B
grinding machine (2)
5 Continue grinding with a small infeed until E The measurements must not be less
the entire circumference of the valve seat is than the test data after this operation.
smooth and free of chatter marks
Additional Information
Engines OM904 LA. 906 LA (mod. d et 904.9, 906.9), F4 15
Outlet valve seat surface machining BE05.30-N-1009-01B
dimension (H) related to valve seat
surface 0 (G)
m 001 589 53 21 00
m 363 589 02 21 00
6 Remove valve (1) from clamp at valve I S Valve grinding machine WH58.30-Z-1022-05A
grinding machine
7 Fit valve (1) onto valve grinding machine CD The valve length (C l, C2) must not be BE05.3Q-N-1006-01B
device (2) and face the end of the valve less than the specification after this
stem operation.
BEDS 3 0 -N .1 0 0 3 -0 1 B V a lv e s e a t a n g le (A ) In le t X 20 20 20
Exhaust A. 45 45 45
BE05.30-N-1005-01B Valve seat width at valve disk (F) Inlet mm 3.3-4.3 3.3-4.3 3.3-4.3
BE05.30-N-1008-01B Inlet valve seat surface machining Dim. G mm 31.0 31.0 31.0
dimension (H) related to valve seat
Dim. H mm 2.7-3.1 2.7-3.1 2.7-3.1
surface 0 (G)
BE05.30-N-1009-01B Exhaust valve seat surface machining Dim. G mm 36.0 36.0 36.0
dimension (H) related to valve seat
Dim. H mm 2.5-3.2 2.53.2 2.5-3.2
surface 0 (G)
BE05.30-N-1010-01B Hardness at valve stem end Inlet HRC 54-60 54-60 54-60
Additional Information
16
r
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 17
AR05.20-W-6292A Removing, installing cam shaft 17.7.95
WOS .20-0001-09
3 Insert engine into engine repair stand I S Engine repair stand WE58.40-Z-1001-11A
I S Adapter WE58.40-Z-1002-11A
18
Additional Information
8 Rotate engine in engine repair stand E Rotate engine approx. 180 so that the
tappets (4) detach from the camshaft (1).
10 Pull out camshaft TDC sensor (B 16) at E Installation: replace O-ring (2) and
crankcase press in camshaft TDC sensor until it makes
contact with camshaft sprocket.
904 589 02 14 00
13 Pull valve tappets (4) out of the crankcase E Mark valve tappets relative to
cronkcose.
Inspecting
m 001 589 53 21 00
Additional Information
Engines O M904 LA, 906 LA (mod. des. 904.9,906.9), F4 19
Test data of camshaft
6E05.20-N-1006-04B Camshaft radial runout when Timing gear seat max. mm 0.020 0.020
mounted on outer bearing journals
Cam base circle max. mm 0.025 0.025
BE05.20-N-1007-04B Cam rise -valve cams over Inlet min. mm 7.3 7.3
base circle 0
Exhaust min. mm 8.2 8.2
WE58.40-Z-1002-11A Adapter
Additional Information
20
AR05.20-W-6292-02A Removing, inserting camshaft
1 Attach I S guide sleeve (2) to front of camshaft (1) and carefully pull camshaft out of
the crankcase.
@
Do not damage camshaft bearings in crankcase.
3 Rotate camshaft (1) until the marking ''1-1 (arrow) on the camshaft sprocket is aligned
with the marking 1 on the crankshaft sprocket (3).
Do not damage camshaft bearings.
BE05.20-N-1006-04B Camshaft radial runout when Timing gear seat max. mm 0.020 0.020
mounted on outer bearing journals
Cam base circle m ax. mm 0.025 0.025
BE05.20-N-1007-04B Cam rise - valve cams over Inlet min. mm 7.3 7.3
base circle 0
Exhaust min. mm 8.2 8.2
BE05.20-N-1006-04B Camshaft radial runout when Timing gear seat max. mm 0.020
mounted on outer bearing journals
Cam base circle max. mm 0.025
a
A hard base should be placed below the cam or bearing
journal to be inspected during the test.
W 05.20-001S-10
Additional Information
22
2 Mount camshaft (l) at the outer bearing journals.
4 Measure cam rise of the valve cams of the inlet valves (E) and
exhaust valves (A) as well as of the unit pump cams (S) with
I S dial gage (3).
WOS .20-0016-12
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 23
AR07.15-W-1628A Removing, installing MR/PLD control unit 1.9.95
1 Spacer
2 Rubber damper
3 Washer
4.1 Nut (ENGINE 904.905 -907/921)
4.2 Bolt (ENGINE 904.909- 911 /922,
906.910/911/920- 923)
5 Vehicle wiring harness connector
6 Engine wiring harness connector
7 Fuel heat exchanger
(ENGINE 904.905 -907/921)
8 Bolt (ENGINE 904.905 - 907/921)
9 Engine trim panel
10 Oil level sensor cable
W07.15-0080-06
m M Removing, installing
Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
2 Tilt cab
5 Detach electric cable of oil level sensor (10) On engine 904.909- 911/922 and
at MR/PLD control unit (A6) 906.910/911/920-923
8 Remove MR/PLD control unit (A6) at @ The MR/PLD control unit must not be
crankcase disassembled
ED Installation: install spacers (1) fitted to
rubber damper (2) and at MR/PLD control
unit. Pay attention to installation position
of rubber dampers (2)
9 Install in t h e reverse o rd er
24
Additional Information
10 Learn transponder keys CD Only If a new MR/PLD control unit (A6) AR80.57-W-0010A
has been installed
Bearbeitungsvermerk
. . . . . . ........ ........................ l'Sit"";
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 25
AS60.80-Z-0001-01A Injury hazard from pinching and crushing When tilting ensure that no one is A Danger!
when cab is tilted present in the tilting area of the cab.
Always tilt cab to end position and
secure with safety brace.
Injury hazard
A damaged tilting mechanism or improper handling of the tilting
mechanism can lead to severe injuries when tilting the cab. When tilting cab:
- Protect tilting area and particularly tilting device against
Rules of behavior/protective measures unauthorized access, e.g. by blocking off or with h u m a n
Before tilting cab: guard.
- Shut off engine. - Attach safety cable before tilting when so specified in the
- Apply parking brake. vehicle operating Instructions.
- Secure vehicle against rolling. N e ve r w o rk u n d e r cah w h e n p a rtia lly tilted .
- On vehicles with manual transmission move shift lever to - Always tilt cab to end position and secure with safety brace.
neutral position.
- On vehicles with automatic transmission move selection lever
to position "N".
AH60.80-N-0003-01A Notes on tilting the cab Models 673,674, 675, 676, 677, 678,
679, 950, 952,953, 954, 957,970,971,
972,973, 974, 975,976
Additional Information
26
AR07.15-W-9235A Removina and installing MR/PLD injection lines
Engine 9QS.920-923 w ith " h y d ra u lic " transm issio n s h ift code CS3
30 Hydraulic lines
31 Securing dips
32 M o u n tin g p la te
33 Bolt
W 2 6 .6 0 -1 0 U -1 1
3 Removal
Danger! Danger of pinching and catching when cab Ensure that no one is present in the tilting Page 26
is tilte d a re a of th e cab w h e n tiltin g . A lw a y s t ilt cab
all the way to the final position and secure
with safety brace.
Notes on tilting the cab Models 673- 679,950- 954,957,970- 976 Page 26
1.2 Remove maintenance hood Models 668,670
Additional Information
8 ^ ^ Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 27
2 Remove hydraulic lines (30) with mounting On engine 906.920- 923 with code (GS3)
plate (32) and mounting clamps (31) from hydraulic gearshift.
engine and lay down to side LLI D o n o t sep ara te h y d ra u lic lines.
A Dangerl Fuel presents an explosion hazard and is Fire, open lights and smoking prohibited. Page 29
toxic when inhaled or absorbed. Contact Avoid sparks. Fill and store fuel only in
with fuel can cause skin and eye injury. containers intended for this purpose and
marked accordingly.
Wear protective clothing when handling
fuel.
SI 000 58907 03 00
SI 000 589 50 03 00
m 000 589 68 03 00
IE Installation
SI 000 589 07 03 OO
SI 000 589 68 03 00
Ezl B A07.15-N-1004-01A
A Danger! Accident hazard resulting from vehicle Secure vehicle against starting to move Page 30
starting to move by itself with engine unintentionally.
running. Danger of Injury resulting from Wear closed and tight fitting work
pinching and burning when reaching in clothing.
during the starting operation or with the Do not touch hot or rotating parts.
engine running.
7 Start engine and allow to run Crank engine for max. 90 seconds with
starter, if it does not start wait approx. 2
minutes and attempt to start again.
10 Install hydraulic lines on engine On 906.920- 923 engine with code (GS3)
hydraulic" gearshift
Additional Information
28
y v . 000 589 50 03 00 J v_ 000 589 68 03 00
AS47.00-Z-0001-01A Risk of explosion from ignition of fuel, risk Fire, the creation of sparks, naked A Danger!
of poisoning if fuel is inhaled or swallowed lights and smoking prohibited.
and risk of injury if skin or eyes come into Only pour fuels into containers which
contact with fuel are suitable and are correspondingly
marked.
W ear protective clothing when
handling fuels.
P o te n tia l d a n g e rs
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 29
ASOO.OO-Z-OOO5-01A Risk of accident as a result of vehicle Secure vehicle to prevent it from A Dangerl
starting off when engine Is running. Risk of moving off.
injury as a result of bruises and burns if you W ear closed and close-fitting work
Insert your hands into engine when it is clothes.
being started or when it is running. Do not grasp hot or rotating parts.
Additional Information
30
AR07.03-W-6831A Removing and installing nozzle holder combination 7.11.97
W 0 7 .03-0001-09
W 0 7 .03-0002-06
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 31
Revisions
m Rem oval
L Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 29
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective dothing when handling
fuel.
5 Press out nozzle holder combination (1) Nozzle holder combination must not be
turned and pulled with a wrench or pliers
otherwise the settings may be altered.
S Insert screwdriver into the top groove
(arrow) of the nozzle holder combination
and press out.
Place protective base on the cylinder
head.
@ Nozzle holder combination must not be
disassembled.
If wear or problem exists 1
3 In s la lla liu n
7 Replace O-ring (5) at the nozzle holder I B Coat O-ring with lubricant BR00.45-2-1018-06A
combination (1)
10 Screw spherical washer (3) and tensioning @ Bolt of tensioning arm, nozzle holder BA07.15-N-1003-01A
arm (4) tight combination and constant throttle to
cylinder head
11 Replace O-ring (7) at the pressure pipte I Coat O-ring with lubricant. BR00.45-Z-1018-06A
c o n n e c tio n (8)
Additional Information
32
12 Install pressure pipe connection (8) and The interference-fit ball (arrow) at the
screw thrust bolt (9) tight pressure pipe connection should be
inserted in to th e slo t (a rro w ) In th e c y lin d er
head.
BR00.45-Z-1018-06A ATE-grease -
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 33
AR07.03-W-6831 C Removing and installing nozzle holder combination 7.11.97
m Removal
34
Additional Information
m 904 589 0063 00
6 Pull out nozzle holder combination (1) @ Nozzle holder combination must not be
disassembled.
If wear or problem exists j,
M Installation
9 Replace O-ring (7) at the nozzle holder IB Coat O-ring with lubricant. B R00.45-Z-1018-06A
combination (1)
12 Screw spherical washer (5) and tensioning @ Bolt of tensioning arm of nozzle holder BA07.15-N-1003-01A
arm (6) tight combination and constant throttle to
cylinder head
13 Replace O-ring (9) at the pressure pipe 3] Coat O-ring with lubricant. BR00.45-Z-1018-06A
connection (10)
14 Install pressure pipe connection (10) and The interference-fit ball (arrow) at the
screw thrust bolt (11) tight pressure pipe connection should be
inserted into the slot (arrow) in the cylinder
head.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 35
@ Diesel injection system with unit pumps (PLD)
Additional Information
36
m
ui I
1.
*
g
S
3
<0
SF
"g
53 #
vosw-M-srzouv
crisartUOM
IS
tn
Additional Information
AR07.15-W-8950A Removing and installing MR/PLD unit pump 1.9.95
W 07.15-0061 -09
mM Removal, installation
1 Remove end cover at timing case Bolt of end cover to timing case BA01.60-N-1002-01A
2 Attach cranking and blocking device for @ Cranking device should be removed Page 39
engine to timing case before starting engine.
HI 904 589 04 63 00
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 29
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
Additional Information
En g in es O M 9 0 4 LA, 906 LA (m o d . des. 904.9, 906.9), F4 37
5 Detach engine wiring harness (7) at unit Slacken bolts at solenoid valve and
pump(1) separate both clips.
L U W h e n rem o vin g th e u n it p u m p o f
cylinder 1 or 2, the attachment strip for the
engine wiring harness with start and stop
switch has to be detached additionally at
the crankcase.
355 589 01 63 00
9 Remove O-rings (2,3,4) at the unit pump [T] Installation: replace O-rings, pay B R00.45-Z-1018-06A
(1) attention to diameter of O-rings and coat
with lubricant.
0 T im ing case
Additional Information
38
S D ie se l in je c tio n s y s te m w it h u n it p u m p s (M R / P L D )
Q04 5RQ 04 63 00
Cranking device
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 39
1 R e m o ve noise e n ca p su la tio n b e lo w th e fly w h e e l ho using.
3 A tta c h I S ] cranking and blo ckin g device (2) t ig h t to fly w h e e l ho using w ith b o lts (4).
I3H Cranking and blocking device (2) can be blocked by inserting the pin (3).
cranking and blocking device (2) must be removed before starting the engine.
W 03.30.Q001-02
Additional Information
40
AR07.15-W-1640B Removing, adjusting and installing crankshaft angle position sensor bracket 7.8.97
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921/922/923/940/941
1 Bracket
2 Shear bolt
3 Securing bush
4 Flywheel
5 I S Cranking device
W07.15-0081 -06
Id Removing
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
El 904 58904 63 00
7 Rotate crankshaft with the cranking device H I Until a mounting hole (arrow) of crank
angle position sensor (B15) is positioned In
the middle at the flywheel (4).
9 Mark flywheel (4) relative to edge in Cl] W ith flywheel removed, mark vibration
inspection hole damper relative to crankcase.
Adjusting
m Installing
15 Remove cranking and blocking device (5) Cranking device should be removed
before starting the engine.
m 904 589 04 63 00
16 Install end cover at timing case Bolt of end cover to timing case B A01.60-N-1002-01A
@ Timing case
Additional Information
42
AR07.15-W-2000D Testing low pressure fuel circuit 22.7.98
1 Fuel feed pump (KFP) 18.2 Throttle (threaded throttle) in flam e start fuel line
1.1 Pressure re lief valve In fuel feed pump (9.2 bar) 19 Short-circuit cable with valve
1.2 N o n -re tu rn valve in fu e l feed pum p (0.2 bar) 20 Fuel m anual feed pum p
2 Fuel filter (KF) 21 Fuel heat exchanger
2.1 Fuel filter drain valve
2.2 Continuous ventilation in fuel filter (as o f engine end no. B 10 Fuel tempera ture sensor
027674) R3 Flam e s ta il plug
3.1 Bypass from fuel supply port to fuel return port Y5 Solenoid valve
5 Nozzle-and-holder assembly
8 Bypass valve up to engine end no. 002 604 6.5 bar Fuel circuit
as o f engine end no. 002 605 4.5 bar A Fuel supply (intake-vacuum side)
8.1 Continuous ventilation (0.5 mm) B Fuel return (leak fuel)
10 PLD unit pumps (Y6 to Y11) C Fuel supply (pressure side)
12 Fuel p refilter (KVF) D Fuel high-pressure side (to PLD unit pumps)
12.1 Non-return valve in fuel pre filter E Fuel return (fuel filter drain)
14.1 Assembly valve in fuel supply (forced opening)
15.1 Assembly valve in fuel return (forced opening) Fuel ports in crankcase
17 Fuel tank Fuel lines
17.1 Ventilation valve
18.1 Throttle (0.5 mm) in flam e start fuel line
Additional Information
Engines O M904 LA, 906 LA (mod. des. 904.9,906.9), F4 43
Test points, test data
C Pressure gauge test III Fuel return flo w quantity at outlet of fuel filter housing
H Fuel return quantity test Idle speed and breakaway speed:
Up to engine end no. 027673 0.1 l/min
I Fuel pressure downstream o f fuel filter As o f engine end no. 027674 0.3 l/min
Idle speed: Up to engine end no. 002604 > 6.0 bar, Fuel return quantity at bypass valve
As o f engine end no. 002605 s 4.3 bar Idle speed: Up to engine end no. 027673 0.9-1.4 l/min
Breakaway As o f engine end no. 027674 0.9-1.7 l/min
speed: Up to engine end no. 002604 6.2 - 7.5 bar, Breakaway
As o f engine end no. 002605 4.0 -6.5 bar. speed: Up to engine end no. 027673 2.0-4.0 l/min
As o f engine end no. 027674 2.7 - 7.5 l/min
II Fuel return flow quantity to nozzle-and-holder assemblies
Testing tim e: 5 minutes IV Fuel intake pressure upstream o f fuel pump
Idle speed: Moist with oil Idle speed: -0.09 to -0.12 bar
Breakaway speed: Max. only drips Breakaway speed: = - 0.35 bar
A Fuel supply
B Fuel return/leak fuel
C Fuel supply (pressure side downstream
o f fuel feed pump and fuel filter)
D Fuel high-pressure side
g in n Removing, installing
/h. Danger! Risk of injury due to being trapped and No-one should be within the tilting range Page 26
crushed when tilting the cab of the cab during tilting. Always tilt the cab
up to its final position and secure with
safety support.
1 Tilt cab
44
Additional Information
Danger! Risk of explosion due to ignition, Fire, sparks, naked flame and smoking Page 29
risk of poisoning due to inhaling and forbidden.
s w a llo w in g fu e l a n d risk o f in ju ry d u e to O n ly p o u r fu els In to s u itab le, a p p ro p ria te ly
fuel coming into contact with skin and marked containers.
eyes. W ear protective clothing when handling
fuel.
3 Carry out visual inspection at all fuel lines, H a IIo w engine to run at breakaway
bolted connections and components speed for approx. 2-3 minutes.
5 Test fuel filter element HlReplace fuel filter element if necessary. WH0780.30
Page 47
Testing
9 Test fuel pressure downstream of fuel filter Attach test and measuring equipment to Page 48
low-pressure fuel circuit.
E 541 58902 21 00
El 000 589 50 03 00
El 000 589 68 03 00
12 Test fuel intake pressure upstream of fuel Attach test and measuring equipment to Page 55
pump. low-pressure fuel circuit.
13 Test low -pressure fu e l c ircu it in e n g in e fo r Attach test and measuring equipment to Page 56
leaks low-pressure fuel circuit.
El 541 589 02 21 00
16 Check vehicle performance on chassis ED Only after all the tests or measurements I
dynamometer. have been carried out and any defects have
been eliminated: 1
If no improvement in fuel consumption or
performance has been achieved a fuel
consumption measuring system is to be
connected.
Additional Information
46
r \ r A r
1 HHT
2 M ultiplexer
3 Adapter cable
4 D iagnostic socket
b First of all connect multiplexer (2) and adapter cable (3) to the e S ta r t te s t p ro g ra m (se e o p e ra tin g in stru ctio n s o f H H T ).
HHT (1).
ED Pay attention to differences related to specific systems which
c Then, connect adapter cable (3) to the diagnostic socket (4). are listed in the relevant diagnosis description in the chapter
"B a s ic k n o w le d g e o f d ia g n o s is ".
Failure to follow the order described may result in the Stored faults which may result from disconnecting cables or
multiplexer being damaged. simulation during test operations, have to be erased in the fault
The HHT program recognizes the control unit type. memory after completing the work.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 47
AR07.15-W-2000-011 Installing test/measuring equipment in low Testing fuel pressure downstream of
pressure fuel circuit fuel filter (fuel circuit)
V 123 5890421 18 J
High-pressure hose
W07.15-1006-09
Shown on engine 904.909 5 Install ring piece HQ (5.2), pressure gauge E (3) and
measuring hose E l (4) on adapter piece (5.1)
1 On MPS or HPS gearshift:
Unscrew lower bolt on bracket/cylinder head. 6 Connect fuel temperature sensor (B10) removed to engine
wiring harness (2) and attach on engine.
2 Remove engine compartment lining (1).
Additional Information
48
AD07.15-W-7001-01D MR (PLD) test of hydraulic system fuel Engines 904.905-907/921 up to engine
pressure downstream of fuel filter end No. 002604
1.0 Check fuel pressure Engine: Start Fuel pressure too high
<s>
downstream of fuel filter Idle speed 600 -650 rpm : > 6.0 bar &(AD07.15-W-5001-09F)
Install testers and
measuring instruments in Breakaway speed Fuel pressure too low
low pressure fuel circuit 2500 rpm: 6.2 to 7.5 bar &(AD07.15-W-7001-06D)
&(AR07.15-W-2000-011)
&(AD07.15-W-7001-06D)
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 49
AR07.15-W-2000-01L Installing test/measuring equipment in low Measuring fuel return flow quantity
pressure fuel circuit of nozzle-and-holder assemblies.
En g in es 904.9, 906.9
a r \ r
Additional Information
50
AD07.15-W-7001-07F MR (PLD) test of hydraulic system fuel Engines 904.905-907/909-911 /921/922
return flow quantity at nozzle holder and 906.910/911/920-923/940/941
co m b in a tio n s
1.0 Check fuel return flow Engine: Start e Fuel or coolant leak at
quantity at nozzle-and- leak oil bore or leak oil line
AR07.15-W-2000-01N Installing test/measuring equipment in low Measuring fuel return flow quantity
pressure fuel circuit Engines 904.905-907/921 up to engine
end No. 040487
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 51
W 0 7 .1 5 -1 0 1 3 -0 9
1 Remove engine compartment lining (1). 5 Install transparent fuel line (7) on I S ring piece (5) and
guide into a clean container (8).
2 Disconnect fuel return line (3) on bypass valve (6).
@ Steady bypass valve (6) when loosening the fuel return 6 Disconnect fuel return line (12) on connection (11) and
line (3). install transparent fuel line (10).
3 Seal fuel return line (3) with banjo bolt (2.1) and I S lock nut [XIThe support (10.1) with opening clamp (arrow) must
W. press the non-return valve into the connection (i i).
4 Detach I S ring piece (5) from bypass valve (6). 7 Guide fuel return line (10) into a clean container (9).
@ Steady bypass valve (6) when tightening bolts.
Additional Information
52
AD07.15-W-7001-06D MR (PLD) test of hydraulic systems fuel Engines 904.905-907/921 up to engine
return flow quantity end NO. 027673
1.0 Fuel return flow quantity Engine: Start e Fuel return flow quantity
at fuel filter housing at bypass valve too low,
o u tle t Idle speed 600 650 rpm w ith in to le ra n ce ra n g e a t
Install testers and Measuring time fuel filter housing outlet
measuring instruments in > 1 minute s 0.1 l/min &(AD07.15-W-5001-08A)
low pressure fuel circuit
&(AR07.15-W-2000-01N) B r e a k a w a y speed Fuel retu rn f lo w q u a n tity
2500 rpm at bypass valve too low,
Measuring time too high at fuel filter
> 30 seconds: 0.1 l/min housing outlet
& (A D 0 7 .15-W-5001-OBB)
Measuring point:
Bypass valve
1.1 Fuel return flow quantity Engine: Start Fuel return flow quantity
at bypass valve at bypass valve, within
Idle speed 600 - 650 rpm tolerance range at bypass
Measuring time valve and fuel filter
> 1 minute 0.9- 1.4 l/min housing outlet
&(AD07.15-W-5001-08D)
Breakaway speed
2500 rpm Fuel return flow quantity
Measuring time at bypass valve and fuel
> 30 seconds: 2.0-4.0 l/min filter housing outlet too
low
&(AD07.15-W-7001-03D)
Additional Information
Engines O M904 LA, 906 LA (mod. des. 904.9, 906.9), F4 53
AD07.15-W-7001-06F MR (PLD) test of hydraulic systems fuel Engines 904.905-907/921 as of engine
return flow quantity end No. 027674
En g in es 904.909 911/922 a n d
906.910/911/920-923/940/941
Measuring point:
Bypass valve
1.1 Fuel return flow quantity Engine: Start Fuel return flow quantity
at bypass valve in order,
at bypass valve
Idle speed 600 - 650 rpm cannot be measured at fuel
Measuring time filter housing outlet
> 1 minute 0.9-1.7 l/mln &(AD07.15-W-5001-08C)
Additional Information
54
AR07.15-W-2000-01P Installing test/measuring equipment in low Testing fuel intake pressure upstream
pressure fuel circuit of fuel supply pump
En g in e 904.905-907/921 up to e n g in e
end no. 040487
\ f
541 589 00 91 00
Adaption parts
2 B lee d fu e l system .
W07.15-1009-06
1.0 Check fuel intake Engine: Start Fuel intake pressure too
pressure upstream of Idle speed 600 - 650 rpm: -0.09 to low (->0 bar)
fuel pump -0.12 bar &(AD07.15-W-5001-01D)
Install testers and Breakaway speed
measuring instruments in 2500 rpm: =-0.35 bar Fuel Intake pressure too
low pressure fuel circuit high (--1 bar)
&(AR07.15-W-2000-01P) &(AD07.15-W-5001-02F)
123 589 04 21 18
W07.15-1011-09
1 Remove engine compartment lining (1). 5 Detach fuel return line (7) on connection (9) and seal with
S I cap (6.3).
2 Remove fuel temperature sensor (BIO).
6 Detach fuel supply line (5) on fuel prefilter housing (8)
3 Install S I adapter piece (6.5) with sealing ring on crankcase. connection and install S I connection line (6.2) with S I shut-
off cock (6.1).
4 Install S I ring piece (6.4), measuring hose (4) and pressure
gauge (3) on adapter piece (6.5).
Additional Information
56
AD07.15-W-7001-08D MR (PLD) test of hydraulic system low Engines 905.905-907/921 up to engine
pressure fuel circuit leaks end no. 040487
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 57
AR07.15-W-2000F Testing low pressure fuel circuit 13.7.98
W07.15-1015-09
Fuel circuit diagram
1 Fuel feed pump (KFP) D Fuel high-pressure side (downstream o f PLD unit pumps)
1.1 Pressure relief valve in fuel feed pump (9.2 bar) E Fuel return (fuel filter drain)
1.2 Non-return valve In fuel feed pump (0.2 bar)
2 Fuel filter (KF) Fuel ports in crankcase
2.1 Fuel filter drain valve Fuel lines
2.2 Continuous ventilation in fuel filter
3.1 Bypass from fuel supply port to fuel return port Test points, test data
5 Nozzle-and-holder assembly G Pressure gauge test
0 Bypass vo/ve (4.5 bar) H Fuel return flow quantity test
8.1 Continuous ventilation (0.5 mm)
10 PLD unit pump (Y6 to Y11) I Fuel pressure downstream o f fuel filter
12 Fuel pre filter (K VF) Idle speed: a 4.3 bar
12.1 Non-return valve In fuel prefllter Breakawayspeed:4.0-6.5bar
14.1 Assembly valve in fuel supply (forced opening) II Fuel return flow quantity to nozzle-and-holder assemblies
15.1 Assembly valve in fuel return (forced opening) Test time 5 minutes
17 Fuel tank Idle speed: M oist w ith oil
17.1 ventvalve Breakaway speed: Max. drips only
18.1 Throttle (0.5 mm) in the flam e start fuel line III Fuel return flow quantity a t outlet o f fuel filter housing
18.2 Throttle (threaded throttle) in flame start fuel line Idle speed and breakaway speed: 0.31/mln
BIO Fuel temperature sensor Fuel return flo w quantity a t bypass valve
R3 Flame start plug Idle speed: 0.9-1.7 l/min
Y5 Solenoid valve Breakaway speed: 2.7- 7.5 l/min
IV Fuel intake pressure upstream o f fuel pump
Fuel circuit Idle speed: -0.09 to -0.12 bar
A Fuel supply (intake/vacuum side) Breakaway speed: -0.4 to -0.5 bar
B Fuel return (leak fuel) V Low-pressure fuel circuit leaktightness
C Fuel supply (pressure side) Test pressure: 10 bar/Testing time 5 minutes:
Pressure drop: s 0.25 bar
Additional Information
58
Fuel circuit diagram
Shown on engine 906
A Fuel supply
B F u e l re tu rn /le a k fu e l W07.15-0083-06
C Fuel supply (pressure side downstream
o f fuel feed pump and fuel filter)
D Fuel high-pressure side (downstream
o f PLD unit pumps)
] HD Removing, installing
/ K Danger! Risk of injury due to being trapped and No-one should be within the tilting range Page 26
crushed when tilting the cab of the cab during tilting. Always tilt the cab
up to its final position and secure with
safety support.
1 Tilt cab
A Danger! Risk of explosion due to ignition, Fire, sparks, naked flame and smoking Page 29
risk of poisoning due to inhaling and forbidden.
swallowing fuel and risk of injury due to Only pour fuels into suitable, appropriately
fuel coming into contact with skin and marked containers.
eyes. W ear protective clothing when handling
fuel.
3 Carry out visual inspection at all fuel lines, [D Allow engine to run at breakaway
bolted connections and components speed for approx. 2-3 minutes.
5 Test fuel filter element CD Replace fuel filter element if necessary. AP47.20-W-0780B
Testing
9 Test fuel pressure downstream of fuel filter Attach test and measuring equipment to Page 48
low-pressure fuel circuit.
El 123 589 04 21 18
ll 541 589 02 21 00
El 541 589 00 91 00
10 Measure fuel return flow quantity at Attach test and measuring equipment to Page 50
nozzle-and-holder assemblies low-pressure fuel circuit.
P^AD Carry out test Page 51
S3 000 589 07 03 00
El 000 589 50 03 00
El 000 589 68 03 00
El 541 589 00 91 00
11 Measure fuel return flow quantity at Attach test and measuring equipment to Page 62
engine low-pressure fuel circuit.
12 Test fuel intake pressure upstream of fuel Attach test and measuring equipment to P a g e 63
pump low-pressure fuel circuit.
El 541 589009100
13 Test low-pressure fuel circuit in engine for Attach test and measuring equipment to Page 65
leaks low-pressure fuel circuit.
l^ A D Carry out test Page 66
El 123 589 04 21 18
60
Additional Information
m 541 58902 21 00
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 61
AR07.15-W-2000-01K Installing test/measuring equipment in low Measuring fuel return flow quantity
pressure fuel circuit Engines 904.909-911/922 and
906.910/911 /9 20-923/940/941.
Engines 904.905-907/921 as of engine
end no. 040488.
Additional Information
62
Shown on engine 904.909
1 Remove engine compartment lining (1). Disconnect fuel return line (12) on fuel filter housing (11),
connection R l" and install transparent fuel line (10).
2 Disconnect fuel return line (3) on bypass valve (6). CDThe support (10.1) with opening clamp (arrow) must
Steady bypass valve (6) when loosening the fuel return press the non-return valve into the connection.
line (3).
Guide fuel return line (10) into a clean container (9).
3 Seal fuel return line (3) with banjo bolt (2.1) and E l lock nut
(4).
AR07.15-W-2000-01J Installing test/measuring equipment in low Testing fuel intake pressure upstream
pressure fuel circuit of fuel supply pump
Engines 904.909-911/922 and
906.910/911/920-923/940/941.
Engines 904.905-907/921 as of engine
end no. 040488.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 63
Shown on engine 904.909
1.0 Check fuel intake Engine: Start Fuel intake pressure too
<$>
pressure upstream of Idle speed 600 - 650 rpm: -0.09 to low (-0 bar)
fu e l pum p - 0 .1 2 b ar & (A D 0 7 .15-W-5001 -01T)
&(AR07.15-W-2000-01J) &(AD07.15-W-5001-02F)
Additional Information
64
AR07.15-W-2000-01M Installing test/measuring equipment in low Testing low-pressure fuel circuit in
pressure fuel circuit engine for leaks
Engines 904.909-911/922 and
906/910/911/920-923/940/941.
Engines 904.905-907/921 as of engine
end No. 040488.
123 589 04 21 18
W 07.15-1010-09
S how n an engine 9 0 4 0 0 0
1 On MPS or HPS gearshift: 6 Detach fuel return line (7) on fuel filter housing (8),
Unscrew lower bolt on bracket/cylinder head connection "RL" and seal with S cap (6.3).
Additional Information
f t s p Engines OM904 LA, 906 LA (m od. des. 904.9,906.9), F4 65
AD07.15-W-7001-08F MR (PLD) test of hydraulic system low Engines 904.905-907/921 as of engine
pressure fuel circuit leaks end No. 040488
E ngin es 904.909-911/922 a n d
906.910/911/920-923/940/941
Additional Information
66
AR09.40-W-591 OA Inspecting turbocharger 18.7.95
W 0 9 .40*0012-06
Inspecting
3 Inspect clearance of rotor shaft (3) EX] If there is no sign of the rotor shaft rub Page 68
bing on either side of the turbocharger
housing, the axial play and radial play are
o.k.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 67
AR09.40-W-5910-01A Inspecting axial play and radial play at If there is any indication of the rotor
rotor shaft shaft touching the turbocharger
housing J
Replace turbocharger
O n e n g in e 904.908/923 AR09.40-D-6020D
m
The rotor shaft is centrifugally
stabilized and is guided in its mount
with a relatively large play.
Additional Information
68
Inspecting radial play: deflect rotor
shaft (1) in radial direction; turn it
when doing this and inspect whether
there is any indication of the turbine
or compressor wheel touching.
m
If there is no sign of the rotor shaft
touching the turbocharger housing on
either side, the radial play is ok. If
there is a sign of it touching, replace
the turbocharger.
replace turbocharger
m
If the control unit is misshapen, the turbocharger has to be
replaced.
m
If the diaphragm is damaged, compressed air escapes
between valve rod (arrows) and control unit mounting.
Replace turbocharger.
Additional Information
Engines O M904 LA, 906 LA (mod. des. 904.9,906.9), F4 69
AR09.40-W-6020A Removing and installing turbocharger 21.11.95
1 Exhaust m anifold
2 Turbocharger
3 Nut
4 Hexagon socket b o lt
5 O il delivery pipe
6 Gasket
7 Gasket
0 O il re tu rn flo w pipe
9 Hexagon socket bolt
10 Bolt
11 Heat shield
12 Mounting
13 Nuts
14 Engine brake flap connection
W09.40-0005-06
F, S 09-5910-6043 Turbocharger
Revisions
Z LD anger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 73
poisoning and burns from swallowing W ear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
70 Additional Information
5 Detach air intake hose (12) ? t turbocharger
(6)
6 Detach exhaust pipe (1) at engine brake Installation: clean sealing surfaces
flap connection (4)
9 Detach oil return flow hose (15) at 00 Collect engine oil which flows out
turbocharger (6)
10 Detach oil pressure line (7) at oil filter and E Seal hole at turbocharger and
turbocharger (6) crankcase.
E Installation: before fitting on the oil
pressure line, fill the turbocharger bearing
housing through the oil filler hole with
engine oil. Rotate turbocharger shaft by
hand during this step so that the bearing
p o ints a re p ro v id e d w ith a n oil film .
Replace seals.
11.2 Take off gasket of oil pressure line at On engine 904.909- 911 /922 and
turbocharger (6) 906.910/911 /920- 923/940/941
E Installation: replace gasket
12 Detach turbocharger (6) together with Seal holes at turbocharger with caps
engine brake flap connection (4) at exhaust E
Installation: replace nuts (5)
manifold
13 Detach engine brake flap connection (14) E Installation: replace nuts (3)
together with bracket (16)
15.1 Check engine oil level with dipstick On engine 904.905- 907/921 WH0101.40
15.2 Check engine oil level at electric gage On eng ine 904.909- 911 /922 and
906.910/911/920- 923/940/941
S e e ATEGO / ECONIC o p e ra tin g instructions
part 3
A Danger Risk ofaccident as a result o( vehicle Secure vehicle to prevent it starting off. Page 30
starting off when engine running. Risk of W ear closed and dose-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 71
16 Start engine and observe oil pressure gage @ Crank engine with starter for not more BE18.00-N-1001-01C
when engine idling than 90 seconds. W ait about 2 minutes
b e fo re re p e a tin g a tte m p t a t starting.
Do not rev up engine so long as no oil
pressure is indicated.
U J The oil pressure gage should indicate
oil pressure after about 10 seconds.
T e st v a lu e s fo r e n g in e o il pressure
@ Turbocharger
M6 Nm 10 10
@ Exhaust manifold
Additional Information
72
AS 54.10-Z-0001-01A Explosion hazard from explosive gas. Flames, sparks, open light and A Danger!
Danger of poisoning and acid burns when smoking prohibited. Wear acid
battery acid is s w a llo w e d . D a n g e r o f acid resistant g loves, clo th in g a n d g o g g les.
burns to skin and eyes from battery acid or Store battery acid only in suitable,
when handling damaged lead-acid appropriately marked containers.
batteries.
Possible dangers
Injury hazard
Explosion hazard Battery acid contains sulfuric acid, which can cause severe burns
A highly explosive gas mixture is generated when lead-acid to skin and eyes. When handling damaged lead-acid batteries
batteries are charged (removing from accident vehicle) increased care is necessary due
to the sharp edges on the broken housing and direct contact with
Poisoning hazard the lead plates.
W hen battery acid is taken orally toxic symptoms can occur such
as headache, dizziness, stomach pain, paralysis of the respiratory Rules of behavior/protective measures
system, unconsciousness, vomiting, acid burns and cramps. - Charge lead-acid batteries only in well ventilated rooms.
Battery acid vapor can burn eyes. Inhalation can result in burns to - Fire, sparks, open light and smoking prohibited.
mucous membranes and respiratory paths. - Do not lay tools or other conductive items on lead-acid
Lead in the body can damage blood, nerves and kidneys; batteries (danger of short circuiting).
moreover, lead compounds pose a hazard for the reproduction - Disconnect and remove lead-acid batteries for charging.
organs. - Always disconnect negative pole first; always connect positive
pole first.
- Switch on charger only after connecting to poles; switch off
before disconnecting.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 73
P54.10-0270-08
7 Fire, sparks, open light and smoking 3 Observe operating instructions 6 Keep aw ay from children
prohibited 4 Danger o f acid burns 7 First aid
2 txplosion hazard 5 w ear eye protection
Do not store lead-acid batteries for extended periods of time Do not switch on battery chargers until they have been
in a place where they are exposed to direct sunlight. connected to the battery poles; switch them off before
Always store lead-acid batteries horizontally to prevent acid disconnecting.
from escaping; do not tilt them when they are being Only charge lead-acid batteries with direct current. For the
transported. charging current we recommend 10% of capacity for normal
Discharged or faulty lead-acid batteries can freeze up; charging and 50% of capacity for rapid charging.
therefore, ensure that they are stored at temperatures above During rapid charging it must be insured that the casing of the
feezing level. lead-acid battery does not warm up excessively (< 55 C).
Do not place any tools or other electrically conductive objects Lead-acid batteries should be kept clean and dry as far as
on a lead-acid battery (risk of short-circuit!). possible.
Avoid mixing up positive and negative poles and avoid short- It is advisable to grease the poles lightly with battery pole
circuits. grease.
Before removing or installing a lead-acid battery, switch off all Lead-acid batteries should not be stored for extended periods
electrical consumers where possible, and switch off the engine, without being recharged.
so as to minimize the possibility of creating sparks. If a lead-acid battery is to remain in a vehicle which is not in
Always disconnect the negative pole first; always connect the use for an extended period, the negative terminal clamp
positive pole first. should be disconnected.
Additional Information
74
AR09.41 -W-1311A Removing, installing boost air pipe 22,11.95
ENGINE 904.90S/906/907/921
W 09.41-0001-06
m m Removing, installing
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cap the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
2 Remove boost air hose (6) Installation: boost air hoses must not be
mixed up.
Red boost air hose is temperature-
resistant and should always be installed
between boost air pipe and intercooier.
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking.
poisoning from inhaling and swallowing Pour fuels only into suitable and Page 29
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
4 Detach solenoid valve (5) together with t ilIf flame starting system fitted collect
bracket fuel which flows out.
5 D iscon n ect c o o la n t p ip e (11) a t b o o s t air OD D o n o t rem o ve c o o la n t pipe.
pipe (1)
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 75
AR09.41 -W-1311C Removing, installing boost air pipe 30.7.97
W09.41-0012-06
mm Removing, installing
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954, 957, 970- 976 Page 26
2 Remove noise encapsulation on right
3 Remove charge air hose, red (8) ED Installation: the charge air hoses must
not be mixed up.
T he red ch arg e a ir hose is tem p e ratu re-
resistant and should always be installed
between charge air pipe and intercooler.
Additional Information
76
AR09.41-W-1311D Removing, installing boost air pipe 31.7.97
H U HU Removing, installing
Danger! Risk of injury from bruises and jamming No person should be In the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as fa r as th e end p o sition a n d secure
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954,957, 970- 976 Page 26
2 Remove noise encapsulation on right
3 Remove black charge air hose (1) DO Installation: boost air hoses must not
be mixed up.
The red charge air hose is temperature-
resistant and should always be installed
between charge air pipe and intercooler.
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 29
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
4 Detach wiring harness (5) and fuel line (6) Flame starting system (code M89) fitted
at the flame glow plug (7) C E Collect fuel which flows out
5 Remove charge air pipe (2) 3 Bolt of charge air pipe to generator BA09.41-N-1004-01B
support
B A 0 9 .4 1 -N -1 0 0 5 -0 1 B N u t o f bo o st a i r p ip e t o b o o st a i r p ip e Nm 30
Additional Information
78
AR09.41 -W-8681A Removing and instailing boost air manifold 1.9.95
ENGINE 904.905/906/907/921
W 09.41-001S-09
is m u Removal, installation
10 Remove boost air temperature sensor (B9) 12 Installation: Replace sealing rings.
and boost pressure sensor (B13)
AS20.00-Z-0001-01A Risk of injury to skin and eyes from Do not open the cooling system unless Danger!
scalding from hot coolant which splashes the coolant temperature is below 90
out..Risk of poisoning from swallowing C. Open cap slowly and allow the
co o la n t. pressure to release.
Do not pour coolant Into containers
for drinks.
W ear protective gloves, protective
clothes, and eye protection.
Additional Information
80
AR09.41 -W-8681C Removing, installing boost air manifold 31.7.97
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 81
0 Boost air pipe/intercooler
Additional Information
82
AR09.41 -W-2003A Removing, installing boost pressure, boost air temperature sensor 4.8.97
W09.41-0017-05
Modification notes
7.7.98 Tightening torque, bolt of boost air pressure, boost air Step 4 Page 83
temperature combination sensor to bootair manifold
added
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 83
AR09.41 -W-6800B Testing intercooler and boost air hoses for leaks 6.8.97
W09.41-0014-06
Testing
^ Danger! Risk of injury from bruises and jamming No person should be in the tilting area of P a g e 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
w ith a s a fe ty prop.
1 Tilt cab
3 Remove screw plug (7) at intercooler (1) CDCollect oil which flows out.
and drain any oil which may have gathered
5 Install test flanges (3, 5) at the boost air 03 Inspect clips for wear.
hoses (2, 6) Test fla n g e s sho uld be s u p p o rted
additionally at the openings of the two
boost air pipes.
SI 904 589 07 63 00
7 Fill intercooler (1) and boost air hoses (2,8) CDTest pressure 1.5 bar.
at test flange (5) with compressed air
84
Additional Information
11 Install noise encapsulation H3 on right and at bottom
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 85
AR13.22-W-1202A Removing, installing poly V-belt 1.9.95
W 1 3 .2 2 -0 0 M .0 6
W13.22-0005-09
Poly V-belt running diagrams
A Standard C W ith ad d itional generator
B W ith AC compressor D W ith AC compressor and additional generator
86
Additional Information
m Removing
s Danger) Risk of injury from bruises and jamming No person should be in the tilting area of Rage 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
3 Use Tommy arm and socket wrench bit (2) Swivel tensioning pulley up only by
to swivel tensioning pulley (1) up and hold means of the bolt (against spring tension)
4 Take off poly V-belt (3) Do not kink poly V-belt when
removing.
Inspect condition of poly V-belt, if
necessary J
6 Inspect vibration damper, belt pulleys of Replace parts which are damaged and/or
the generator and of coolant pump and worn: 1
also tensioning device and tensioning
pulley (1)
m Installing
7 Fit poly V-belt (3) onto the belt pulleys and CD Do not fit poly V-belt onto tensioning
the vibration damper pulley (1).
8 Swivel tensioning pulley (1) Up and fit poly @ Swivel tensioning pulley up only by
V-belt (3) onto the tensioning pulley means of the bolt.
[D Inspect correct installation of poly
V-belt on the belt pulleys.
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as fa r as th e en d p o sitio n a n d secure
with a safety prop.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 87
AR13.25-W-3200A Removing, installing poly V-belt tensioning device 18J.95
W 1 3 .25 00 01 -0 6
B IE S Removing, installing
1 Remove poly V-belt (4) Engine 904.905- 909/910- 921/922 and Page 86
906.910/911/920- 923/940/941
2 Take off tensioning device (2) [D Installation: fix pins at the tensioning
d e vice in to t h e h o les a t th e o il filte r hou-
sing (3).
3 Install in th e reverse o rd e r
Additional Information
88
AR13.30-W-551 OA Removing, installing compressor 18.7.95
I Compressor
9 O-ring
10 Drive gear
II Nut
13 Cross plate
18 W1 Blocking device
18a Nut
19 S3 Puller
W 13.30-0039-06
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 89
30 Hydraulic lines
31 Securing clips
32 M ounting plate
33 Bolt
W 26.60 -1 01 1-11
Modification notes
m M Removing, installing
A Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 26
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
3.2 Remove shift rod at cylinder head Engine 904.909- 911/922 and 906.910/911
3.3 Detach hydraulic lines (30) together with Engine 906.920-923 with "hydraulic" shift
mounting plate (32) and securing dips (31) code GS3
at engine and place to the side S Do not separate hydraulic lines
4.1 Remove MR 1PLD control unit Engine 904.905- 907 /909- 911 /921 /922 Page 24
906.910/911/920-923
4.2 Separate plug connection at control valve Engine 906.910/911/920- 923
of constant throttle
5 Pull out crankshaft angle position sensor S Installation: press in TDC sensor
(B is ) at timing case, detach cable and cable cylinder 1 and crankshaft angle position
of TDC sensor cylinder 1 (B16) sensor as far as a stop
Additional Information
90
, Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Pa g e 80
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
and eye protection.
9 Detach suction line (6) at compressor (1) 0 Connection of suction line to BA13.30-N-1008-01A
compressor
10 Separate both steering lines (16,17) at the Counterhold connection fitting in power
separation point steering pump when slackening and collect
hydraulic fluid which flows out
LU Installation: top up hydraulic fluid and
bleed steering
11 Remove compressor (1) together with Collect engine oil which flows out
power steering pump (14) from the I I I Installation: fully tighten the inner top
crankcase hexagon bolt (12) first of all, then the
remaining bolts
13 Slacken nut (11) and pull off drive gear (10) Attach blocking device (18) at compressor
at compressor (1) and then unscrew nut
(11)
G2 904 589 03 63 00
17.1 Check engine oil level with dipstick Engine 904.905-907/921 WH0101.40
17.2 Check engine oil level at electric gage Engine 904.909- 911/922 and
906.910/911/920-923
See ATEGO opration instructions part 3
WH58.30-2-1001-17A Three-legged puller (300 mm width) Hahn und Kolb 55 051 040
Borsigstr. 50
D-70469 Stuttgart
Additional Information
92
ASOO.OO-Z-O013-01A Risk of injury to skin or eyes from Before starting work on the hydraulic A Danger!
pressurized hydraulic fluid spraying out. system, depressurize the system. Wear
Risk of poisoning from swallowing protective clothing and safety glasses.
hydraulic fluid
Potential danger
Risk of injury - Ensure only authorized persons have access to hydraulic fluid.
Serious injuries can be caused to the skin or eyes when loosening - Seal disconnected lines and hoses and connections on the
hydraulic lines without depressurizing the system beforehand, subassemblies immediately with blind plugs.
due to the very high pressures (above 200 bar). Damage to the - Wear safety gloves, protective clothing and safety glasses.
skin may be caused if unprotected skin comes into contact with If it is not possible to wear safety gloves, the following points are
hydraulic fluid, particularly central hydraulic fluid (this is to be observed:
especially harmful to health). - Only allow hydraulic fluid to come into contact with the skin
for as short a time as possible, wash fluid off skin with soap
Risk of poisoning and water.
Anyone who swallows hydraulic fluid can expect to suffer - Change wet clothing as quickly as possible
symptoms of poisoning including headaches, dizziness, stomach
ache, vomiting, diarrhoea, cramps and unconsciousness First aid
Have the casualty drink plenty of water with activated charcoal
Safety measures/operating instructions additive.
- Before starting work on hydraulic systems they should be After swallowing larger quantities .consult a doctor.
depressurized and the system must be emptied if necessary. If hydraulic fluid gets into the eyes, rinse out the eyes
- Do not pour hydraulic fluid into drinking containers. immediately with plenty of clean water/using a eye rinsing
- Ensure adequate ventilation, particularly in the case of central glass.
hydraulic fluid. In the event of injuries to skin or eyes from a jet of hydraulic
fluid, consulta doctor immediately.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 93
AR14.10-W-3915A Removing, installing exhaust manifold 22.11.95
Removing, Installing
A Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 6
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
b a tte ry e lec tro ly te. Risk o f in ju ry to eyes eye p ro te c tio n . P o u r b a tte r y e le c tro ly te
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
5 Detach exhaust pipe (17) at engine brake Installation: clean sealing surfaces
flap connection (14)
7 Detach heat shield (12) at turbocharger (9) LAJ Installation: Engine 904.905-907/921:
and crankcase attach heat shield and compressor suction
line together at crankcase
8 Detach oil return flow hose (11) at [ E Collect engine oil which flows out
turbocharger (9)
9 Detach oil delivery line (8) at oil filter and Seal hole at turbocharger in crankcase.
turbocharger (9) HI Installation: before attaching the oil
pressure line, fill the turbocharger bearing
housing through the oil filler hole with
engine oil. Rotate turbocharger shaft by
hand during this step so that the bearing
points are provided with a film of oil.
12 Inspect exhaust manifold bolts (3) CD Installation: if the max. shank length BE14.10-N-1001-01A
(L) was exceeded j
14 Detach turbocharger (9) together with EE Seal holes at turbocharger with caps
exhaust brake flap connection (14) at
exhaust manifold (2)
16.2 Check engine oil at electric gage Engine 904.909/910- 922 and
906.910/911 /920- 923/940/941
See ATEGO operating instructions part 3
4
Additional Information
A Danger Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 9
starting off when engine running. Risk of Wear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
17 Start engine and observe oil pressure gage Crank engine w ith starter for not more BE 18.00-N-1001 -01C
when engine idling than 90 seconds. W ait about 2 minutes
before repeating attempt at starting.
Do not rev up engine so long as no oil
pressure is indicated.
LU The oil pressure gage should indicate
oil pressure after about 10 seconds.
0 Turbocharger
M6 Nm 10 10
Additional Information
3rd stage 90
AS 54.10 -Z -0 0 0 1-01A Explosion hazard from explosive gas. Flames, sparks, open light and A Danger!
Danger of poisoning and acid burns when smoking prohibited. Wear acid
battery acid is swallowed. Danger of acid resistant gloves, clothing and goggles.
burns to skin and eyes from battery acid or Store battery acid only in suitable,
when handling damaged lead-acid appropriately marked containers.
batteries.
Possible dangers
Injury hazard
Explosion hazard Battery acid contains sulfuric acid, which can cause severe burns
A highly explosive gas mixture is generated when lead-acid to skin and eyes. When handling damaged lead-acid batteries
batteries are charged (removing from accident vehicle) Increased care is necessary due
to the sharp edges on the broken housing and direct contact with
Poisoning hazard the lead plates.
When battery acid is taken orally toxic symptoms can occur such
as headache, dizziness, stomach pain, paralysis of the respiratory Rules of behavior/protective measures
system, unconsciousness, vomiting, acid burns and cramps. - Charge lead-acid batteries only in well ventilated rooms.
Battery acid vapor can burn eyes. Inhalation can result in burns to Fire, sparks, open light and smoking prohibited.
mucous membranes and respiratory paths. - Do not lay tools or other conductive items on lead-acid
Lead in the body can damage blood, nerves and kidneys; batteries (danger of short circuiting).
moreover, lead compounds pose a hazard for the reproduction - Disconnect and remove lead-acid batteries for charging.
organs. - Always disconnect negative pole first; always connect positive
pole first.
Switch on charger only after connecting to poles; switch off
before disconnecting.
Additional Information
6
- Keep lead-acid batteries and battery acid away from First-aid measures
unauthorized persons. Eye contact
- Store battery acid only in suitable, appropriately marked Rinse eyes immediately with large quantities of water.
containers. Skin contact
- Store lead-acid batteries only in upright position. Remove affected clothing.
- Ensure that gassing line is properly connected. Neutralize acid on skin or clothing immediately with acid
Check gassing line fo r kinks and proper passage neutralizar o r soap solution and rinse w ith large quantities
- Observe instructions for applicable lead-acid battery and of water.
vehicle operating instructions. Inhalation of battery acid vapor
- Wear acid protective clothing and protective goggles with side Move affected person to fresh air
guard. Swallowing battery acid
Have person drink large quantities of water containing
activated charcoal.
P54.10-0270-08
Fire, sparks, open light and smoking 3 Observe operating instructions 6 Keep aw ay from children
p rohibited 4 D anger o f od d burns 7 First aid
2 Explosion hazard 5 W ear eye protection
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 7
AH 54.10-P-0001 -01A Notes on battery All models
Do not store lead-add batteries tor extended periods of time Do not switch on battery chargers until they have been
in a place where they are exposed to direct sunlight. connected to the battery poles; switch them off before
Always store lead-acid batteries horizontally to prevent acid disconnecting.
from escaping; do not tilt them when they are being Only charge lead-acid batteries with direct current. For the
transported. charging current we recommend 10% of capacity for normal
Discharged or faulty lead-acid batteries can freeze up; charging and 50% of capacity for rapid charging.
therefore, ensure that they are stored at temperatures above During rapid charging it must be insured that the casing of the
feezing level. lead-acid battery does not warm up excessively (< 55 C).
Do not place any tools or other electrically conductive objects Lead-acid batteries should be kept clean and dry as far as
on a lead-acid battery (risk of short-circuit!). possible.
Avoid mixing up positive and negative poles and avoid short- It is advisable to grease the poles lightly with battery pole
circuits. grease.
Before removing or installing a lead-acid battery, switch off all Lead-acid batteries should not be stored for extended periods
electrical consumers where possible, and switch off the engine, without being recharged.
so as to minimize the possibility of creating sparks. If a lead-acid battery is to remain in a vehicle which is not in
Always disconnect the negative pole first; always connect the use for an extended period, the negative terminal clamp
positive pole first. should be disconnected.
Bearbeitungsvermerk
[ Datum j rsteiier Vermerk [Seite
AS60.80-Z-0001-01A Injury hazard from pinching and crushing W hen tilting ensure that no one is A Danger!
when cab is tilted present in the tilting area of the cab.
A lw ays tilt cab to end position and
secure with safety brace.
Injury hazard
A damaged tilting mechanism or improper handling of the tilting
mechanism can lead to severe injuries when tilting the cab. W hen tilting cab;
- Protect tilting area and particularly tilting device against
Rules of behavior/protective measures unauthorized access, e.g. by blocking off or with human
Before tilting cab: guard.
- Shut off engine. - Attach safety cable before tilting when so specified in the
- Apply parking brake. vehicle operating instructions.
- Secure vehicle against rolling. - Never work under cab when partially tilted.
- On vehicles with manual transmission move shift lever to - Always tilt cab to end position and secure with safety brace.
neutral position.
- On vehicles with automatic transmission move selection lever
to position N".
Additional Information
8
AH60.80-N-0003-01A Notes on tilting the cab Models 673,674,675,676,677,678,
679,950,952,953,954,957,970,971,
972, 973, 974, 975, 976
ASOO-00-Z-0005-01A Risk of accident as a result of vehicle Secure vehicle to prevent it from A Danger!
starting off when engine is running. Risk of moving off.
injury as a result of bruises and burns if you Wear closed and close-fitting work
insert your hands into engine when it is clothes.
being started or when it is running. Do not grasp hot or rotating parts.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 9
AR14.15-W-6302A Removing, installing engine brake flap connection 20.11.95
W 1 4 ,15-0001-12
1 1 Removing, installing
Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 6
poisoning and burns from swallowing W ear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
2 Tilt cab
5 Detach exhaust pipe (1) at engine brake 2 ] Installation: clean sealing surfaces
flap connection (3)
Additional Information
10
6 Detach compressed air line (10) at engine
brake cylinder
7 Detach engine brake flap connection (3) CH! Installation: replace nuts (4)
and fixture (5)
0 Exhaust manifold
Additional Information
W14.15-1002-06
U HU Removing, installing
A Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 6
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
2 Tilt cab
5 Remove exhaust pipe (1) at engine brake EX] Installation: clean sealing surfaces and
flap connection (3) and at the rear lifting inspect clip (2) for wear, replace clip if
eye necessary
12
Additional Information
0 Nut of engine brake flap connection to BA14.10-N-1002-01B
turbocharger
0 Exhaust manifold
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 13
AR14.15-W-581OA Repairing engine brake flap connection 1.9.95
Disassembling
5 Remove engine brake flap (4) CD Close engine brake flap for this step.
6 R em o v e e n g in e b ra k e sh a ft (3) a n d b e a rin g C l] Use a suitable drift.
bushes (2)
0 Assembling
14
Additional Information
7 Install bearing bush (2) on the bracket side tilw ith a projection (approx. 3 mm) to the
inner contact surface.
Use a suitable drift.
8 Insert engine brake flap (4) into the engine iXI Coat bearing point with hot lubricating B R00.45-Z-1006-06A
brake flap connection (1) and push engine paste.
brake shaft (3) through
9 Knock in second bearing bush (2) EE Center engine brake shaft (3) to brake
flap connection diameter. Projection of
both bearing bushes to inner contact
surface should be the same.
Use a suitable drift.
10 Knock back bearing bushes (2) evenly on in Use a suitable drift. BE14.15-N-1004-01B
both sides until the axial play (A) of the
engine brake shaft (3) is achieved
11 Bolt engine brake flap (4) tight [I] When engine brake flap closed, bolt
heads (5) should be pointing toward
engine. Center engine brake flap in engine
brake flap connection (1). In closed
position, engine brake flap should be
resting against flap connection stop.
12 Measure annular gap at engine brake QJ Engine brake flap must not be making
flap (4) contact radially at flap connection passage
when closed.
14 Install adjusting lever (9) 0D Fit adjusting lever onto the splines of
the engine brake shaft (3) so that the
adjusting lever stop is resting against
bracket (6) when engine brake flap (4) is
fully open (position B).
15 Inspect setting of engine brake flap (4) When engine brake flap is closed
(position C). adjusting lever stop must not
be touching the bracket (6) (distance
approx. 1 mm).
17 Set preload of engine brake cylinder (13) HI When engine brake flap (4) opened BE 14.15-N-1002-01B
and secure engine brake cylinder (position B), turn the ball socket (11)
(approx. 2 turns) until the specified setting
is achieved
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 15
Tesi data of engine brake
W H 8 3 0 -Z -1 0 0 8 -1 3 A E e e le r g a g e Stie fe lm o y c r 59
D-73734 Esslingen
Repair products
Additional Information
16
AR14.15-W-5810F Repairing engine brake flap connection 9.7.98
Disassembling
6 Remove engine brake flap (4) E For this purpose close engine brake flap
7 Remove engine brake shaft (3) and bearing E Use suitable punch.
sockets (2.1, 2.2)
8 Install bearing socket (2.2) on retainer side E With protrusion (approx. 3 mm)
pointing toward Inner contact surface
Use suitable punch.
9 Install engine brake flap (4) in engine E Coat bearing surface with high BR00.45-Z-1006-06A
brake throttle valve housing (1) and slide temperature lubricating paste.
engine brake shaft (3) through
10 Knock in second bearing socket (2.1) E Center engine brake shaft (3) in
throttle valve housing diameter. The
protrusion of both bearing sockets
pointing toward the inner contact surface
must be uniform. Use suitable punch.
12 Tighten engine brake flap (4) E Bolt heads (5) should point toward
engine with engine brake flap closed.
Center engine brake flap in engine brake
throttle valve housing (1).
Engine brake flap should be In contact with
throttle valve housing stop In closed
position.
13 Measure annular gap on engine brake flap E Engine brake flap should not make
(4) radial contact with throttle valve housing
passage in closed position.
16 Check engine brake flap (4) adjustment When the engine brake flap is open
(position B) the adjustment lever should
not make contact with the bracket (6)
(interval approx. 1 mm)
19 Adjust initial tension of engine brake S Turn ball socket (10) (approx. 2 turns) BE14.15-N-1002-01B
cylinder (13) and secure engine brake with engine brake flap (4) open (position
cylinder B) until predefined adjustment value is
reached.
Additional Information
18
Test values for engine brake
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 19
AR15.30-W-7100A Removing, installing starter 19.7.95
W 15.30-0004'1 2
M M Removing, installing
Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 6
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
2 Tilt cab
4 Detach wiring harness (6) at bracket (5) On engine 904.909- 911/922 and
906.910/911/920- 923/940/941
20 Additional Information
7 Detach cables (1,2) at starter (M1)
replace starter
@ Starter
Repair products
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 21
AR15.40-W-5032A Removing and installing generator 22.11.95
ENGINE 904.905 /906 /907 /909 /910/911 /921 /922.906.910/911 /920 /921 /922 /923 /940 /941
1 A ir intake hose
2 Bolt
3 Poly V-belt
4 Nut
5 Bolt
6 Supporting bracket
7 Bolt
e W iring harness
9 Bracket
G1 Generator
W 15.40.0004-0$
F, S 15-5030- Generator
5076
Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 6
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
2 Tilt cab
5 Remove charge air pipe from intercooler to On engine 904.909- 911/922 and AR09.41-W-1311D
charge air manifold 906.910/911/920- 923/940/941
22
Additional Information
7 Slacken poly V-belt (3) and take off H I At tensioning pulley and belt pulley of AR13.22-W-1202A
generator
8 Disconnect wiring harness (8) at generator E Pay attention to color coding of cables
(G1)
12 Take generator (G1) off support (6) 0 Nut of generator to support BA15.40-N-1002-01 B
0 Generator
Additional Information
E n gin es O M 9 4 LA . 90fi I A (m o d d es 94 9. 906.9). 64 23
AR15.40-W-571 OA Removing and installing the generator poly V-belt pulley 1.8.97
W 15.40-0006-06
Modification notes
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954, 970- 976 Page 9
2 Remove noise encapsulation S on right and at bottom
4 Slacken nut (2) at the belt pulley (3) E Counterhold generator shaft with
hexagon socket wrench
5 Slacken poly V-belt (1) and take off E at tensioning pulley and belt pulley (3) AR13.22-W-1202A
of generator
6 Detach belt pulley (3) and fan wheel (4) at
generator
Additional Information
24
H Generator
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 25
AR18.10-W-6020A Removing, installing oil pump 22.11.95
ENGINE 904.905/906/907/909/910/91119211922.906.910/911/920/9211922/923
ENGINE 904.908/923 in MODEL 668. 670
ENGINE 906.940/941 in MODEL 957
1 OH pump
2 B olt
3 Dowel pins
4 O-ring
5 Connection fitting
6 Drive gear
7 Dipstick guide tube
8 Bracket
9 Bolt
10 Nuts
11 Bolts
12 Intake pipe
13 Bolt
14 Radial seal
WI8.10-0002-06
1 Oil pump
3 Dowel pin
5 Connection fitting
14 Radialseal
15 IS D rift
16 Guide sleeve
17 Base
W 18.10*0006-06
u s in i Removing, installing
26 Additional Information
Engine 904.908/923 AR01.45-D-7500D
3 Take off dipstick guide tube (7) and brac H I Installation: attach dipstick guide tube
ket (8) at suction pipe (12) and bracket free of stress.
4 Take off suction pipe (12) 0 Bolt of suction pipe to oil pump BA18.10-N-1002-01B
El 904 589 02 15 00
m 904 589 02 15 00
8 Inspect contact surface of crankshaft for ED If wear exists, a radial seal with race has
signs of scoring or rubbing been available from about 10/96 for
repaiis.
0 Timing case
B A 1 S .1 0 -N 1 0 0 1 -0 1 B B o lt o f o il pu m p to crankcase Nm 25 25
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 27
Repair products
Additional Information
28
AR18.30-W-6840A Removing, installing oil-water heat exchanger 19.7.95
ENGINE 904.905/906/907/909 /910 /911 /921 /922, 906.910/911 /920 /921 /922 /923 /940 /941
is m s Removing, installing
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cap the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with safety prop.
1 Tilt cab
Notes re tilting cab Models 673- 679, 950- 954,957,970- 976 Page 9
2 Remove noise encapsulation on right [ S on right
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 29
A Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
and eye protection.
El 366 589 01 07 00
5 Remove boost air pipe from intercooler to Engine 904.909-911/922 and AR09.41-W-1311D
boost air manifold 906.910/911 /920- 923/940/941
9 Disconnect oil delivery pipe (7) at turbo EE Collect engine oil which flows out.
charger and take off gasket (11) Seal oil drilling in turbocharger.
12 Remove oil-water heat exchanger (1) at ED Collect coolant and engine oil which
crankcase flows out.
30
Additional Information
14 Detach housing cover (1,2) from the heat HI Installation: do not tighten bolt (1.1)
exchanger (1.3) until after attaching the oil-water heat ex
changer to the crankcase.
15 Remove gasket (1.4) from housing cover H i Installation: replace gasket (1.4).
(1.2)
@ Turbocharger
M6 Nm 10 10
0 Exhaust manifold
Additional Information
Eng ines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 31
0 Oil filter
Number Designation Engine 904.905/
906/907/909/
910/911/921/922.
906.910/911/919/
920/921/922/923
/940/941
Additional Information
32
AS20.00-Z-0001 -01A Risk of injury to skin and eyes from Do not open the cooling system unless Danger!
scalding from hot coolant which splashes the coolant temperature is below 90
out..Risk of poisoning from swallowing C. Open cap slowly and allow the
coolant. pressure to release.
Do not pour coolant into containers
for drinks.
Wear protective gloves, protective
clothes, and eye protection.
Coolant composition
Passenger car and commercial vehicle engine (normal case): @ A concentration of anticorrosion/antifreeze agent higher than
50 % by volume water and 55 % by volume should not be used as the maximum antifreeze
50 % by volume anticorrosion/antifreeze agent. protection is thus reached. An even higher concentration again
See MB Specifications for Service Products for differing coolant reduces the antifreeze protection and impairs heat dissipation.
composition for commercial vehicle engines.
W ater
Purposes of anticorrosion/antifreeze agent Use water which is clean and not too hard. Drinking water
Corrosion and cavitation protection for all components in the frequently, but not always, satisfies the requirements. The
cooling system contents of dissolved substances in the water can be of
A n tifre e z e p ro tection im p o rta n c e fo r th e o ccu rren ce o f co n u sio n . In cases o f d o ub t,
Increasing boiling point so that the coolant does not evaporate analyze the water. See MB Specifications for Service Products for
so rapidly. Ejection of coolant is avoided at high coolant fresh water regulations.
temperatures.
operation of monitoring of coolant
Antifreeze protection Inspect coolant for resistance to low temperatures before the start
50 % by volume of anticorrosion/antifreeze concentration offers of the cold season of the year.
antifreeze protection down to approx. -37 C. In countries with high ambient temperatures, inspect the
A higher concentration is only practical at even lower ambient anticorrosion/antifreeze concentration once a year.
temperatures. The corrosion protection in the coolant is reduced during
55 % by volume of anticorrosion/antifreeze concentration offers operation. Such coolants have a severely corrosive effect.
antifreeze protection down to approx. -45 C. The maximum permissible period of use of the coolant is for
passenger car and commercial vehicle engines (normal case)
3 years.
See MB Specifications for Service Products for the period of use
for differing coolant composition for commercial vehicle engines.
Additional Information
i e v Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 33
Disposing of coolants
Before pouring fresh coolant into the system, flush the used Observe legal regulations and local wastewater regulations.
coolant out of the cooling system. Clean cooling system if severe For workshops located in the Federal Republic of Germany see:
soiling or oil contamination exist. "Umweltschutz-Handbuch fr Kfz-Reparaturbetriebe"
(Environm ental protection manual for vehicle repair
workshops)
Publisher: Verband der Automobilindustrie e.V. (VDA)
D-60625 Frankfurt am Main, Westendstrae 61
Additional Information
34
AR18.20-W-3471A Removing, installing oil filter housing 22.11.95
ENGINE 904.90S/906/907/909 /910/911 /921 /922,906.910/911 /920 /921 /922 /923 /940 /941
(S ig n Removing, installing
A Danger Risk of explosion from gas. Risk of No fire, sparks, naked flames or smoking. Page 6
poisoning and burns from swallowing Wear acid-resistant gloves, clothing and
battery electrolyte. Risk of injury to eyes eye protection. Pour battery electrolyte
and skin as result of caustic burns from only into suitable and appropriately
battery electrolyte or from handling marked containers.
damaged lead-acid batteries.
1 Disconnect battery
2 Tilt cab
5 Detach bracket (13) at coolant pump On engine 904.909- 911/922 and BA20.10-N-1005-01C
906.910/911/920- 923/940/941
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 35
7 Unscrew oil filter cap (7.2) [2 When the oil filter cap is unscrewed,
the engine oil flows back Into the oil pan
366 5890107 00
8.2 Unplug connector of engine wiring harness On engine 904.909- 911/922 and
(14) at oil temperature, oil pressure sensor 906.910/911 /920- 923/940/941
(B11/B12)
9 Detach bracket (4) at oil filter housing (7) 0 Bolt of bracket ot oil filter housing BA15.40-N-1001-01B
10 Detach generator (G2) and swivel bracket 0 Bolt of generator to bracket BA 15.40-N-1003-01B
(4) and generator away from oil filter
housing (7)
12 Take out oil filter cap (7.2) together with IX] Collect engine oil which drips out of oil
oil filter element filter element (7.1)
re p la c e seal (7.3)
13 Detach oil filter housing (7) at crankcase S3 Collect engine oil which flows out
14 Take gasket (10) out of oil filter housing (7) S3 Installation: replace seal
15 Install in the reverse order
16 Adjust engine oil to correct level On engine 904.905- 907/921 Wartung LKW Band 1,
0101.40
A Danger Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 9
starting off when engine running. Risk of W ear closed and dose-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
Additional Information
36
17 Start engine and observe oil pressure gage Crank engine with the starter for not B E18.00-N-1001 -01C
when engine idling more than 90 seconds. W ait about 2
minutes before repeating attempt at
starting. Do not rev up engine so long as no
oil pressure is indicated.
B ] The oil pressure gage should indicate
oil pressure after about 10 seconds.
@ Generator
0 Oil filter
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 37
a Coolant pump, coolant thermostat
Additional Information
38
AR18.20-W-5050A Removing, installing oil filter bypass valve 1.9.95
W 18.20-0002-06
n a gn Removing, Installing
A Danger! Risk of Injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cap the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
3 Unscrew oil filter cap (1.1) from oil filter U | when oil filter cap is unscrewed, the
housing (1) engine oil flows back into the oil pan
366 5890107 00
m 366 589 01 07 00
5 Remove screw plug (5) H The screw plug is pressed out by the
spring (3).
Additional Information
S9^ Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 39
6 Take out spring (3) and oil filter bypass 00 Installing: check that oil filter bypass
valve (2) and inspect for damage valve is correctly located in oil filter
housing (1); install spring for this purpose.
When installed, spring should project
about 1 cm at oil filter housing.
8 Adjust engine oil to the correct level Engine 904.905- 907/921 WH0101.40
9 Start engine and check oil pressure gauge @ Crank engine w ith the starter for not BE18.00-N-1001-01C
w ith e n g in e id lin g m o re th a n 20 seconds. W a i t ap p ro x.
2 minutes before making a repeat attempt
at starting.
Do not rev up engine so long as no oil
pressure is in d ica te d .
LLI The oil pressure gage should indicate
oil pressure after approx. 10 seconds.
0 Oil filter
Additional Information
40
S Oil level sensor, oll pressure sensor
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 41
AR18.40-W-4133A Removing, installing oil pressure, oil temperature sensor 4.8.97
Modification notes
7.7.98 Tightening torque for oil pressure and oil temperature Step 6 Page 42
combination sensor to oil filter housing added
M M Removing, Installing
Danger! Risk of injury from bruises and jamming No person should be In the tilting area of Page 8
when tilting cab the cab when it is being tilted. Always tilt
cab os fo r as th e e n d p o sition a n d secure
with a safety prop.
1 Tilt cab
N o tes o n tiltin g cob M o d e l 673- 679, 950- 954, 957, 970- 976 Page 9
4 Unscrew oil filter cap from oil filter housing ID The engine oil flows back into the oil
pan when the oil filter cap is removed.
replace seal.
6 Remove oil pressure, oil temperature E l Collect engine oil which flows o u t.
sensor (2)
42
Additional Information
7 Install in the reverse order
/h> Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 9
starting off when engine running. Risk of Wear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
8 Start engine and check oil pressure gage Crank engine with the starter for not BE18.00-N-1001-01C
when engine idling more than 90 seconds. Wait approx.
2 minutes before making a repeat attempt
at starting.
Do not rev up engine so long as no oil
pressure is indicated.
Li] The oil pressure gage should indicate
oil pressure after approx. 10 seconds.
0 Oil filter
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 43
Additional Information
AR18.40-W-4111A Removing and installing oil level sensor 6.8.97
1 Oil pan
2 Clip
3 Engine wiring harness
4 seal
Removing, installing
4 Remove oil level sensor (B14) at the oil pan EDInspect seal (4), if necessary J,
(1)
rep la ce seal
m WH 58.30-Z-1037-06A
6 Inspect engine oil level at electric indicator LLi See ATEGO / ECONIC operating
instructions Part 3
A Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Page 9
starting off when engine running. Risk of W ear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 45
7 Start engine and check oil pressure gage Crank engine with the starter for not BE18.00-N-1001-01C
when engine idling more than 90 seconds. W ait approx.
2 m in u tes b e fo re m ak in g a re p e a t a tte m p t
at starting.
Do not rev up engine so long as no oil
pressure is indicated.
LLI T h e o il pressure g a g e sho uld in d ic a te
oil pressure after approx. 10 seconds.
m ax im u m speed bar 2 2 .5
Additional Information
46
AR18.00-W-4000A Removing, installing oil spray nozzles (piston cooling) 22.11.95
ENGINE 904.905/906/907/909/910/911/921/922,906.910/911/920/921/922/923
EN G IN E 9 0 4 .9 0 8 /9 2 3 in M O D E L 66 8, 6 7 0
ENGINE 906.940/941 in MODEL 957
1 OH spray nozzle
2 D anjo b o lt
W18.O0-OQQ2-OS
M Removing, installing
2 Detach cover at timing case 0 Bolt of end cover to timing case BA01.60-N-1002-01A
3 Attach cranking and blocking device (3) to G] Block cranking and blocking device by Page 48
the timing case inserting the pin
[3 904 589 04 63 00
5 Remove oil spray nozzle (1) CO Installation: the dowel pinatthe oil
spray nozzle should engage in the hole in
the crankcase (arrow).
0 Timing case
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 47
904 58904 63 00 J
Cranking device
0 Timing case
3 Attach 13 cranking and blocking device (2) tight to flywheel housing with bolts (4).
Q ] Cranking and blocking device (2) can be blocked by inserting the pin (3).
@ Cranking and blocking device (2) must be removed before starting the engine.
W 0 3 .30.0001-02
Additional Information
AR18.00-W-1600A Filling engine oil circuit 19.7.95
ENGINE 90 4.90 5/90 6/90 7/90 9 /910 /911 /921 /9 2 2 ,906.910 /9 1 1 /920 /921 /922 /923
ENGINE 904.908/923 in MODEL 668,670
ENGINE 906.940/941 in MODEL 957
1 Screw plug
2 Seal
3 I S Union fitting (M 14X1.5)
4 m o u reservoir
5 I S Shutoff valve
6 O il-w ate r heat exchanger
W lS .00 -0 00 1-0 6
S3 Removing
2.1 Remove noise encapsulation on right Model 904.905- 907/909- 911/921 /922 and
906.910/911 /92Q- 923/940/941
3 Remove the screw plug (1) at the oil-water LU Installation: replace seal (2).
heat exchanger (6)
4 Screw adapter fitting (3) tight E l Use adapter fitting (M14X1.5) 352 58911 63 00
Filling
8 Open shutoff valve (S) long enough until E l The pressure in the oil reservoir should
approx. 4 liters of engine oil has been not drop below 1.5 bar; re-pump if
pumped from the oil reservoir (4) into the necessary.
oil galleries and the engine oil flows out Do not completely empty oil reservoir
free of bubbles at the rocker arms (arrows) otherwise air will be forced in.
El 352 589 11 63 00
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 49
10 Top up remaining engine oil at the filler Engine 904.905-907/921 WH0101.40
neck
11.1 Check engine oil level with dipstick Engine 904.905-907/921 WH0101.40
11.2 Check engine oil level at electric indicator Engine 904.909- 911 /922 and
906.910/911/920- 923/940/941
See ATEGO Operating Instructions Part 3
A Danger! Risk of accident as a result of vehicle Secure vehicle to prevent it starting off. Pa g e 9
starting off when engine running. Risk of Wear closed and close-fitting work clothes.
injury as a result of bruises and burns if you Do not grasp hot or rotating parts.
insert your hands into engine when it is
being started or when it is running.
12 Start engine and check oil pressure gage at @ Crank engine with the starter for not BE18.00-N-1001-01C
idle speed more than 90 seconds. W ait approx.
2 minutes before making a repeat attempt
a t starting .
Do not rev up engine so long as no oil
pressure is indicated.
0D The oil pressure gage should indicate
oil pressure a fte r ap p ro x. 10 seconds.
Additional Information
50
V 352 589 11 63 00 y
Adapter fitting
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 51
AR20.10-W-1271A Removing and installing coolant pump 22.11.95
M M Removal, installation
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954, 957,970- 976 Page 9
2 Remove sound proofing capsule S on left and right
6 R em o ve p u lle y (3)
7.1 Remove bracket (19) on boost air manifold Engines 904.905- 907/921
or boost air pipe
7.2 Remove bracket (21) on boost air pipe and Engines 904.909/- 911/922 and
coolant pump (4) 906.910/911/920- 923/940/941
Additional Information
52
8 Disconnect engine wiring harness
connector (13) from coolant temperature
sensors
12 Remove coolant pump (4) and gasket (14) IX! Installation: Replace gasket.
0 Bolt for coolant pump on crankcase BA20.10-N-1001-01C
Additional Information
Engines OM904 LA, 906 1A (mnri Hec 904 9. 906.9), F4 53
1 Remove coolant lines (1,2) from connector (3).
W 2 0 .1 0 -0 0 1 4 -H
Additional Information
54
AR20.10-W-1401A Disassembling and assembling coolant pump 19.7.95
W 20.10-0003 06
1 Flange
2 Retaining ring
3 Bearing and shaft
5 Cassette-type seal
6 im peller
9 S Punch
s Disassembly
Additional Information
Engines QM9Q4 LA. 906 LA (m n ri Hpc qn Q, Q06 Q). FA 55
2 Use puller (7) and thrust piece (8) to pull 000 589 65 33 00
flange (1) off the bearing shaft (3)
4 Use a suitable drift to press bearing (3) out IS Stationary workshop press WE58.40-Z-1001-12A
of the impeller (6) and coolant pump
housing (4)
0 Assembling
6 Oil bearing (3) with engine oil at bearing Press in bearing only at bearing outer
outer race and use a suitable drift to press race.
it into coolant pump housing (4)
/ h Danger! Injury hazard to skin and eyes when Wear protective gloves, protective clothing Page 57
handling hot or glowing objects and, if required, protective goggles
8 Heat flange (1) and press onto bearing @ Counter-hold at shaft when pressing BE20.1Q-N-1002-01B
with shaft (3) on.
Measure size (B) distance between coolant
pump housing (4) and flange (contact
surface of belt pulley).
9 Fit new cassette-type seal (5) over the shaft m 352 5890815 00
(3) and use a drift to press in as far as D inspect seat of cassette-type seal on
coolant pump housing (4) shaft and in coolant pump housing.
10 Press impeller (6) onto the shaft (3) Counter-hold at shaft when pressing
on.
12 Install coolant pump Engines 904.905- 907/909- 911 /921 /922 Page 52
and 906.910/911 /920- 923/940/941
Additional Information
56
Test data of coolant pump
'N r
WE58.40-Z-1001-12A Stationary workshop press 651 , e.g. Matra-Werke GmbH, D-60314 Frankfurt/Main
ASOO.OO-Z-O0O2-O1A Risk of injury to skin and eyes from Wear heat resistant gloves, protective A Danger!
handling hot or glowing objects clothing and protective goggles if
necessary
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 57
AR20.10-W-2460A Removing and installing engine coolant thermostat 22.11.95
W 20.10-0015-12
A Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature Is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant release. Do not pour coolant into
containers for drinks.
W ear protective gloves, protective clothes,
and eye protection.
58
Additional Information
3 Remove coolant pipe (4) Q ] Collect coolant which flows out.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 59
AR20.10-W-2455A Testing coolant thermostat 19.7.95
W 2 0 .10-0005*04
1 Coolant thermostat
1/1 M ain valve
W 2 0 .10-1001-01
SI Testing
Danger! Risk of injury to skin and eyes through Wear safety gloves, protective clothes and Page 57
handling hot or glowing objects if necessary, eye protection.
3 Use a suitable source of heat to heat the On no account use a welding torch or
water. Stir water so that the water soldering iron for heating the coolant
temperature is the same at all points. thermostat (1).
4 Measure water temperature CDThe rate at which the water is heated BE20.10-N-1001-02A
up should not be more than 1to 2C/min.
fro m a b o u t 8 C b e lo w th e sta rt o f o p e n in g
of the coolant thermostat. Pay attention to
standard or tropical version of coolant
thermostat (1).
BE20.10-N-1001-02B
5.1 Heat water to the full opening CDExcept engine 906.920-923 BE20.10-N-1003-02A
temperature of the bypass valve (112)
BE20.10-N-1003-02B
6 Heat water to the full opening CDThe main valve (1/1) must be fully open BE20.10-N-1002-02A
temperature of the main valve (1/1) and after 6 to 8 minutes. If the test values are
measure stroke not achieved J,
60 Additional Information
BE20.10-N-1002-026
7 Install coolant thermostat (1) On engine 904.905 -907/909- 911/921 /922 Page 58
and 906.910/911/920- 923/940/941
On engine 904.908 in model 668,670
T est d a ta o f c o o la n t th e rm o s ta t
DE20.10-N-1001-02A C o o la n t th e rm o s ta t - sta rt o f o p en in g C 83 + 2
Stroke in mm S 8 a8
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 61
AR20.40-W-6800A Removing and installing fan shroud 4.8.97
W20.40-0004-09
1 Radiator with intercooler 5 Coolant hose (heating)
2 Fan shroud 6 Coolant hose (coolant pum p)
3 C oolant hose (coolant line) 7 Cable strap
4 Coolant hose (heating)
O lJ Removing, installing
Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
and eye protection.
4 Detach coolant hose (3) at the coolant line H I Collect coolant which flows out.
and at radiator (1)
5 Separate coolant hoses (4,5) and detach H I Collect coolant which flows out.
coolant hose (5) at connection piece
62
Additional Information
7 Remove coolant hose (4) at radiator (1)
8 Remove fan shroud (2) at radiator (1) H I Fan shroud is secured at the two top
radiator mounting brackets and inserted at
bottom.
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 63
AR20.40-W-5614C Removing and installing fan 5.8.97
W20.40-0003-06
Operation no. of operation texts or standard texts and flat rates
@ 1 Removing, installing
A Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
3 Remove boost air pipe from turbocharger Engine 904.909- 911/922 and AR09.41-W-1311C
to intercooler 906.910/911/920- 923/940/941
4 Remove boost air pipe from intercooler to Engine 904.909- 911 /922 and AR09.41-W-1311D
boost air manifold 906.910/911/920- 923/940/941
Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from s w a llo w in g cap slo w ly a n d a llo w th e p ressure to
coolant. release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
an d ey e p ro te c tio n .
64
Additional Information
Notes on coolant Page 33
6 Remove coolant hoses at the coolant oumo Engine 904.909- 911 /922 and
and connector piece 906.910/911 /920- 923/940/941
7 Detach viscous fan clutch (1) together with E E Installation: viscous fan clutch together
fan (2) at intermediate piece and take out with fan should be stored upright for at
least 1 hour before being installed.
8 Detach viscous fan clutch (1) at fan (2) @ Fan to viscous fan clutch BA20.40-N-1001 -01B
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 65
AR20.20-W-3865A Removing, installing radiator 23.10.95
ENGINE 904.905/906/907/921
Removing, installing
& Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant release. Do not pour coolant into
containers for drinks.
W ear protective gloves, protective clothes,
and eye protection.
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cap the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
5 Till cab
66
Additional Information
Notes re tilting cab Page 9
8 Remove boost air hoses (6,7) H I Installation: boost air hoses must not
be mixed up.
@ Red boost air hose (7) is temperature-
resistant and should always be installed
between boost air pipe and intercooler.
9 Detach coolant hoses (4, 5,9,10) at the [E l Collect coolant which flows out.
coolant lines and at radiator (1)
10 R e m o v e b ra ck e t (3) o n rig h t o f ra d ia to r, t a
ke off mounting bracket with coolant pi
pes, oil filler pipe (2) and place to the front
and tie up
Additional Information
iS S fl* Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 67
AR20.20-W-3865C Removing and installing radiator 4.8.97
S S Removing, installing
1 O p e n service flap
2 Remove protective grille (14) in front of ED Remove from front
intercooler
3 R e m o v e h e a t e x ch a n g er (12) a t in te r c o o le r If A C fitte d
HI Do not damage heat exchanger and tie
up at cab mounting. Do not disconnect
coolant lines.
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
Additional Information
68
Dangerl Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
and eye protection.
7 Remove boost air hoses (2,3) CD Installation: boost air hoses must not
be mixed up.
Red boost air hose (2) is temperature-
resistant and should always be installed
between boost air pipe and intercooler.
9 Detach coolant hoses (5,7,8,16) at the CD Collect coolant which flows out.
coolant lines and at radiator (1)
10 Detach coolant hoses (5,7) at engine E collect coolant which flows out.
13 Remove radiator with intercooler (1) at CD Inspect radiator mountings (11) for
bottom at frame crossmember signs of wear, if necessary j
replace radiatormountings(ll).
15 Remove fan shroud (2) at radiator (1) CD Fan shroud is secured at the two top
radiator mounting brackets and inserted at
bottom.
Additional Information
Engines OM904 LA, 906 LA (mod. de$. 904.9,906.9), F4 69
AR20.20-W-3865F Removing and installing radiator 4.6.98
mm Removing, installing
Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
and eye protection.
70
Additional Information
7 Detach transmission oil lines (14) at bottom E Collect transmission oil which flows
of radiator(1) out. Seal openings with plugs.
A Danger Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
8 Tilt cab
n Remove charge air hoses (7,8) 00 inspect condition of charge air hoses
and hose clips, replace if necessary
12 Detach coolant hoses (3,9,10,11) at [XI Collect coolant which flows out. Inspect
radiator and cooling expansion reservoir or condition of coolant hoses and hose clips,
engine (1) replace If necesssary
17 Lift radiator up and out together with Do not damage radiator, intercooler
in terco o ler a n d c o o la n t expansion a n d c o o la n t ex p an sion reservoir
reservoir (1)
21 Inspect transmission oil level IX Top up oil to bottom edge of oil filler AP26.00-W-2601A
opening
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 71
/223-T
<2) < ) <8>@
@ @ @ @ 0
2224-T
n n
40 40 45 45
UL UU UJ
CDCDiDCDCl]
000 589 01 1000
T o rx b it set
Additional Information
72
AR20.00-W-1030A Removing grease and scale in cooling system 1.9.95
W2O.OO-0OO1-12
Degreasing
i Danger! Danger of severe burns to skin and eyes Open cooling system only when coolant Page 33
from hot coolant spewing out. Coolant is temperature is below 90 C. Open cover
toxic when swallowed slowly and reduce pressure. Do not fill
beverage containers with coolant. Wear
protective gloves, protective clothing and
protective goggles.
P3 Croni BR00.45-Z-1011-04A
Additional Information
Engines OM904 LA. 906 LA (mod. des. 904.9.906 9), F4 73
> Danger! Accident hazard resulting from vehicle Secure vehicle against starting to move Page 9
starting to move by Itself with engine unintentionally.
ru n n in g . D a n g e r o f in ju ry re su ltin g fro m W e a r closed a n d t ig h t fitt in g w o rk
pinching and burning when reaching in clothing.
during the starting operation or with the Do not touch hot or rotating parts.
engine running.
Replace thermostat.
17 Install th e rm o s ta t P a g e 58
18 Fill cooling system with specified coolant Engines 904.905- 907 WH2080
and check for leakage
E n g in e 904.908/923 AP20.00-D-Z080A
Additional Information
74
@ Coolant pump, coolant thermostat
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9,906.9), F4 75
AR20.00-W-101 OB Cheeking cooling system for leaks 4.8.97
W20.00-0004-11
Testing
A Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the Page 33
scalding from hot coolant which splashes coolant temperature is below 90 C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
containers for drinks.
Wear protective gloves, protective clothes,
and eye protection.
m 655 589 00 63 00
5 Fill cooling system at tester (4) with CD Test pressure approx. 1.0 bar. A
compressed air pressure drop is visible at the pressure gage
if there is a leak in the cooling system, if
necessary J,
Additional Information
76
8 Screw on cap (1) tight at expansion E Adjust coolant to correct level AP20.00-W-2010A
reservoir(2)
Additional Information
Engines OM904 LA, 906 LA (mod. des. 904.9, 906.9), F4 77
AR20.30-W-4392A Removing and installing coolant level sensor 1.8.97
is m Removing, installing
, Danger Risk of injury to skin and eyes from Do not open the cooling system unless the Pa g e 33
scalding fro m h o t c o o la n t w h ich splashes c o o la n t te m p e ra tu re Is b e lo w 90 C. O p e n
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into
containers for drinks.
W e a r p ro te c tive g loves, p ro te c tiv e clothes,
and eye protection.
N o tes o n c o o la n t P a g e 33
Additional Information
78
AR46.30-W-0500A Removing and installing power steering pump 20.6.97
W 46.30-0009-06
l) E 3 Removing, installing
A Danger! Risk of injury from bruises and jamming No person should be In the tilting area of Page 8
when tilting cab the cab when it Is being tilted. Always tilt
cab as fa r as th e e n d po sitio n a n d secure
with a safety prop.
A Danger! Risk of injury to skin or eyes as a result of Render system pressureless before Page 80
hydraulic fluid spraying out under high commencing work on hydraulic system.
pressure. Risk of poisoning from Wear protective clothes and eye
swallowing hydraulic fluid. protection.
3 Separate both hoses at the steering lines Collect hydraulic fluid which flows out.
(16,17) E E Installation: top up hydraulic fluid.
4 Detach power steering pump (14) at the @ Bolt of power steering pump to com BA46.30-N-1001-01B
compressor (1) pressor
6 Detach hoses at the power steering pump E Counterhold connection fitting In the
(14) power steering pump when slackening;
collect hydraulic fluid which flows out.
ASOO.OO-Z-0013-01A Risk of injury to skin or eyes from Before starting work on the hydraulic A Danger!
pressurized hydraulic fluid spraying out. system, depressurize the system. Wear
Risk of poisoning from swallowing protective clothing and safety glasses.
hydraulic fluid
Potential danger
Risk of injury - Ensure only authorized persons have access to hydraulic fluid.
Serious injuries can be caused to the skin or eyes when loosening - Seal disconnected lines and hoses and connections on the
hydraulic lines without depressurizing the system beforehand, subassemblies immediately with blind plugs.
due to the very high pressures (above 200 bar). Damage to the - W ear safety gloves, protective clothing and safety glasses.
skin may be caused if unprotected skin comes into contact with If it is not possible to wear safety gloves, the following points are
hydraulic fluid, particularly central hydraulic fluid (this is to be observed:
especially harmful to health). - Only allow hydraulic fluid to come into contact with the skin
for as short a time as possible, wash fluid off skin with soap
Risk of poisoning and water.
Anyone who swallows hydraulic fluid can expect to suffer - Change wet clothing as quickly as possible
symptoms of poisoning including headaches, dizziness, stomach
ache, vomiting, diarrhoea, cramps and unconsciousness First aid
Have the casualty drink plenty of water with activated charcoal
Safety measures/operating instructions additive.
- Before starting work on hydraulic systems they should be After swallowing larger quantities .consult a doctor.
depressurized and the system must be emptied if necessary. If hydraulic fluid gets into the eyes, rinse out the eyes
- Do not pour hydraulic fluid into drinking containers. immediately with plenty of clean water/using a eye rinsing
- Ensure adequate ventilation, particularly in the case of central glass.
hydraulic fluid. In the event of injuries to skin or eyes from a jet of hydraulic
fluid, consult a doctor immediately.
Additional Information
80
AR47.20-W-1070A Removing, installing fuel full-fiow filter 7.11.97
W 4 7 .20-0002-06
Modification notes
MM Removing, installing
Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
w h e n tiltin g cab th e cab w h e n it is b e in g tilte d . A lw a y s tilt
cab as far as the end position and secure
with a safety prop.
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 82
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
2 Unscrew fuel filter cap (1) together with ID When the fuel filter cap is removed, the
fuel filter element (3) fuel flows out of the fuel filter housing
b ack a lo n g th e fu e l re tu rn f lo w lin e in to
the fuel tank.
D Installation: inspect seal (2), replace if
necessary.
3 Pull dirt collection reservoir (4) out of the D Dispose of fuel and the impurities
fuel filter housing (5) which have gathered in the dirt collection
reservoir
5 Detach fuel line (15) at fuel filter housing E if flam e starting system fitted
(5) collect fuel which flows out.
Installation: replace seals (12).
6 Detach fuel filter housing at crankcase S Collect fuel which flows out.
Installation: replace gasket (6).
S Fuel filter
AS47.00-Z-0001-01A Risk of explosion from ignition of fuel, risk Fire, the creation of sparks, naked A Danger!
o f p o iso n in g if fu e l is in h a le d o r s w a llo w e d lights a n d smoking prohibited.
and risk of injury if skin or eyes come into Only pour fuels into containers which
contact with fuel are suitable and are correspondingly
marked.
Wear protective clothing when
handling fuels.
Potential dangers
Additional Information
82
AR47.20-W-1070C Removing, installing fuel full-flow filter 7.11.97
W47.20-0003-06
Modification notes
IE! SU R e m o v in g , in stallin g
/is Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cab the cab when it is being tilted. Always tilt
cab as far as the end position and secure
with a safety prop.
1 Tilt cab
Notes on tilting cab Model 673- 679,950- 954,957, 970- 976 Page 9
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 82
poisoning from Inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers,
coming into contact with skin and eyes. w ear protective clothing when handling
fuel.
2 Unscrew fuel filter cap (1) together with E When the fuel filter cap is removed, the
fupl filtp r p lpm pnt ( ? ) fuel flows out of the fuel filter housing
back along the fuel return flow line into
the fuel tank.
E Installation: inspect seal (2), replace If
necessary.
3 Pull dirt collection reservoir (4) out of the E Dispose of fuel and the impurities
fu e l filte r h o u sin g <S) w h ic h h a v e g a th e re d in th e d irt co llectio n
reservoir.
4 Detach fuel lines (10,11) at fuel filter E Mark fuel lines and collect fuel which
housing (5) flows out.
6 Detach fuel line (14) at fuel filter housing H I If flame starting system fitted
(5) collect fuel which flows out.
Installation: replace seals.
7 Detach fuel filter housing at cranltcase H Collect fuel which flows out.
Installation: replace gasket (6).
Fuel filter
Additional Information
84
AR47.21-W-5621A Removing, installing fuel heat exchanger 7.11.97
[S U E ] Removing, installing
S Danger! Risk of injury from bruises and jamming No person should be in the tilting area of Page 8
when tilting cab the cab when it is being tilted. Always tilt
ca b as fa r as th e en d p o sition a n d secure
with a safety prop.
A Danger! Risk of explosion from ignition. Risk of No fire, naked flame or smoking. Page 82
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of injury as a result of fuel appropriately marked containers.
coming into contact with skin and eyes. Wear protective clothing when handling
fuel.
2 Unscrew fuel filter cap (8) from the fuel E E When the fuel filter cap Is removed, the
filter housing fuel flows out of the fuel filter housing
back along the fuel return flow line into
th e fu e l tank.
E E Installation: replace seal (9).
4 Detach fuel heat exchanger (1) at PLD @ Fuel heat exchanger must not be
controil unit(A6) disassembled.
0 Fuel pump
exchanger
0 Fuel filter
Additional Information
86
AR47.20-W-5713A Removing and installing fuel pumps 7.11.97
W 47.20-0001-06
HH Removing, installing
A Danger! Risk of Injury from bruises and jamming No person should be in the tilting area of Page 8
w h e n liiiin g td b th e cub w h e n it is being tilted . A lw a y s tilt
cab as far as the end position and secure
with a safety prop.
Notes on tilting cab Model 673- 679,950- 954, 957, 970- 976 Page 9
1.2 Remove service hood Model 668, 670
2 Slacken poly V-belt (1) and take off ax belt Engine 904.905- 907/909- 911/921 /922 and AR13.22-W-1202A
pulley of coolant pump 906.910/911 /920- 923/940/941
3.1 Detach guide pulley (3) at the fuel pump E If At. fitted
(5)
A Danger! Risk of explosion from Ignition. Risk of No fire, naked flame or smoking. Page 82
poisoning from inhaling and swallowing Pour fuels only into suitable and
fuel. Risk of Injury as a result of fuel appropriately marked containers.
coming Into contact with skin and eyes. W ear protective clothing when handling
fuel.
4 Unscrew fuel filter cap (10) from the fuel H When the fuel filter cap is removed, the
filter housing fuel flows out of the fuel filter housing
back along the fuel return flow line into
the fuel tank.
E Installation: replace seal (11).
5 Detach fuel line (8) at the fuel pump (5) H Collect fuel which flows out.
Installation: replace seals (7).
s3 Fuel pump
0 Fuel f ilte r
Additional Information
88
From the Library of Barrington Diesel Club