Workshop Manual MTU4000R41

MTU_ValueService
Technical Documentation

Diesel Engine
12 V 4000 R41
16 V 4000 R41

Workshop Manual
M020124/02E

Printed in Germany
2009 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the
prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution,
translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or
damage during operation.
Subject to alterations and amendments.
Table of Contents 01
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03
Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Instructions for Major Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Diesel Engine 12V 4000 R41 / 16V 4000 R41 (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949
Instructions for Major Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 959
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1841
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02 Table of Contents
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General Information 03
General Information
1 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
1.1 Prerequisites for maintenance work and general assembly instructions . . . . . . . . . . . 05
1.2 Reman assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
2 General Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
2.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
2.2 Personnel and organizational requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Auxiliary materials, fire prevention and environmental protection . . . . . . . . . . . . . . . . 14
2.5 Standards for warning notices in the publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 General information regarding the Tolerances and Wear Limits List . . . . . . . . . . . . . . . 17
2.7 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Tightening specifications for screws, nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.10 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.11 Repairing threaded bores with threaded inserts (Heli-Coil) . . . . . . . . . . . . . . . . . . . . . . 44
2.12 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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Important Notes 05
1 Important Notes
1.1 Prerequisites for maintenance work and general
assembly instructions
This Workshop Manual is for technicians responsible for maintenance.
Contents: Extended component maintenance
Observe the following sequences:
Disassemble engine.
Assemble engine.
Prerequisites for maintenance work
For maintenance work performed by the customer, the following conditions must be fulfilled:
All safety regulations are to be observed.
Deployment of trained and qualified personnel.
Suitable workshop equipment with general tools.
Suitable test equipment.
Approved special tools.
General assembly instructions
For assembly work, use new sealing and securing elements.
Components that are exposed to contact with oil, fuel, coolant and combustion air must be clean. Components with
the requirement "particularly clean" (e.g. components carrying oil and fuel) should be cleaned in the appropriate
manner and checked for cleanness. Remove packaging of components immediately before assembly.
Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.
Remove oil or fuel coatings. The parts should be wiped with a dry cloth.
Elastomer components such as engine mounts, damping elements, couplings and V-belts must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
Radial-lip shaft seals treated by the manufacturer with oil show, as a result, definite signs of swelling when delivered.
They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
The surfaces of parts that slide against each other must be lubricated with SAE30 engine
oil when installed, unless otherwise specified.
O-rings and surfaces moving against them during installation (bores and shafts) must be coated with grease, unless
otherwise specified. When installing O-rings with counterrings in coolant pumps, always follow the installation
instructions. After installing O-rings in shaft grooves, pass a rounded marking tool under the O-ring in the direction
of the circumference if the O-ring diameter is sufficiently large. Make sure that the O-ring is not damaged.
Before assembling shaft seals:
On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft
running surface with thin-film lubricant or SAE 30 engine oil.
In support bores, in the case of a metal outer jacket, the outer surface must be coated with surface sealant,
unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer
outer jackets, the outer surface must be coated with denatured ethanol.
This symbol applies to radial-lip shaft seals and its significance depends on its position. The
arrow indicates the position of the sealing lip.
Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on the
flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be fitted
to the component and then (no more than 20 minutes later) the seal components screwed together.
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Before installing antifriction bearings, lubricate the bearing seats. Only remove the bearings from their
original packaging immediately before installation. Do not remove the corrosion inhibitor from the
bearings in the original packaging. Use petroleum spirit or acid-free kerosene to clean the antifriction
bearings. After cleaning, lubricate the bearings with engine oil SAE 30.
During assembly, do not apply any (axial) force to rolling elements and do not hit the
bearing rings with a hammer (use assembly aids).
Do not use a naked flame to heat bearing inner races.
The temperature must be between 80 C and 100 C and never exceed 120 C.
Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
Do not oil dry bearings.
When assembling gears, the splines must be lubricated with SAE 30 engine oil.
All contact and mating faces of components (e.g. mating faces for centering devices, flange and sealing faces, joint
faces of press fittings) must be clean, polished or provided with the specified surface protection and free from surface
irregularities and damage. Corrosion inhibitor (e.g. oil, grease) must be removed from the contact and mating faces.
After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate
must be removed and the parts coated with SAE 30 engine oil.
Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
Line connections with cutting ring unions must be preassembled and tightened in a vice, after
the threads have been coated with thin-film lubricant.
If components are marked by etching, after the etching is completed the solution must be removed by means
of neutralization agent. The affected parts must then be preserved with SAE 30 engine oil.
Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the contact
and mating faces with assembly compound, unless otherwise specified.
The mounting faces of screws, nuts, washers and of parts to be tensioned must be clean and polished or
provided with the specified surface protection and free from surface irregularities and damage. Corrosion
inhibitors (e.g. oil, grease) must be removed. Thread and screw mating faces must be coated with
lubricant before installation in accordance with the tightening specifications.
Unless otherwise specified, use engine oil SAE 30 as a lubricant and assembly compound in hot-component areas.
For threaded connections without tightening specifications, the tightening procedure can be selected
as required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end
wrench or box wrench is possible. When machine-tightening is carried out, look up tightening torque
of thread size and strength class in the general tightening specifications.
Threaded connections with tightening specifications:
The threaded connections must be tightened manually with a click wrench or angle-of-rotation torque
wrench. The specified tightening torques must be set without considering the specified tolerance
at the click wrench. When using an angle-of-rotation torque wrench, the torque indicated must be
within the torque specification limit value. Proceed in a similar manner with torsionally protected
threaded connections. This information also applies to checking torques.
If no tolerance is specified for a tightening torque, the tightening tolerance is + 10% of specified torque.
Angle-of-rotation tightening:
The angles of further rotation specified in the tightening specifications must be attained and may be
exceeded within the specified tolerance. If no tightening tolerance is specified, the following tolerances
must be observed: +5 for additional angle of rotation less than or equal to 90 +10 for additional
angle of rotation greater than 90. Before angle-of-rotation tightening, each screw head must be
colormarked so that after tightening it is possible to check that the angle of rotation is correct (exception:
colormarking is not necessary in the case of a selfmonitoring NC screwdriver).
Elongated tightening:
Carry out tightening according to tightening specifications, taking tightening tolerance into account.
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Important Notes 07
1.2 Reman assemblies
Reman assemblies
The following assemblies are only available via the exchange procedure:
Series 2000 Series 4000
Injector Injector
HP fuel pump HP fuel pump
Crankshaft Crankshaft
Cylinder head Cylinder head
Conrod Conrod
Crankcase Crankcase
Intercooler Intercooler
Piston Piston
Exhaust turbocharger Exhaust turbocharger
Coupling
Vibration damper
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General Conditions 09
2 General Conditions
2.1 General Instructions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
Incorrect use
Operation, maintenance and repair by unqualified personnel
Modifications or conversions
Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized engine modifications compromise safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis--vis the engine manufacturer will be accepted.
Reworking components
During repair or engine overhaul reworking can be carried out in workshops authorized by MTU.
However, no generally valid instructions can be issued for the reworking of components as
the machining tools available on site may differ.
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2.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
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2.3 Safety precautions when working on the engine
Safety precautions when putting the equipment into operation
Prior to initial operation, the product must have been installed correctly and approved according to MTUspecifications.
Before putting the device or the system into operation, always ensure
that all maintenance and repair work is completed
that all loose components have been removed from rotating parts
that nobody is standing in the danger zone of moving engine components.
Safety requirements for operators
Procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the display instruments and monitoring units must be permanently observed with regard
to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
notify the supervisory personnel in charge
analyze the message
if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Compliance with maintenance and repair specifications is an important safety factor.
Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure
the engine against inadvertent starting. With electric starter, disconnect the battery. With pneumatic starter, close
main shut-off valve of compressed-air system and release pressure from compressed-air supply line. Attach sign
"Do not operate" in operating area or to control equipment. Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance and repair work must only be carried out by authorized, qualified personnel.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane.
Always support these components in accordance with regulations on suitable frames or stands
before beginning any maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check
that all guards have been installed and that all tools and loose components have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when
installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
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Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fire
or temperatures above 300 C the material degenerates, giving off hydrogen fluoride gas. Hydrogen fluoride
vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch
elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers Risk of burning!
Note cooling period for components which are heated for installation or removal Risk of burning!
Do not touch hot components of the compressor and the exhaust system Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. Risk of burning!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable binding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
Use lifting gear or seek assistance.
Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Observe special cleanness when conducting maintenance and repair work on the engine plant. After completion
of maintenance and repair work, make sure that no loose objects are in/on the engine plant.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. The welding
current could be induced in the cable harnesses and could possibly damage the electrical plant.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
For hydraulic installation, screw on the tool with the piston retracted.
For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
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Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
Prior to working on assemblies, the power of the appropriate areas must be switched off. Any measures
requiring power supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
Always tighten connectors with connector pliers.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
Laser devices of classes 1, 2 or 3A,
Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
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2.4 Auxiliary materials, fire prevention and environmental
protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
noises indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, which
means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling
hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.
Lead
When working with lead or lead-containing pastes, avoid direct contact with the
skin and do not inhale lead vapors.
Adopt suitable measures to avoid the formation of lead dust!
Switch on fume extraction system.
After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
Immediately remove clothing wetted by acids and alkalis!
Rinse injuries with plenty of water!
Rinse eyes immediately with eyedrops or clean tap water.
Painting
When painting in other than spray booths equipped with extractors, ensure good ventilation.
Make sure that adjacent work areas are not affected.
No naked flames!
No smoking.
Observe fire prevention regulations!
It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.
Wear protective clothing, gloves, closed shoes and protective goggles!
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Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffocation.
Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air tanks and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
Pay special attention to the pressure level in the compressed air network and pressure vessel!
Connecting devices and equipment must either be designed for this pressure or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
Always wear protective goggles when blowing off tools or extracting chips!
The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being reflected and thereby prevents injury to eyes.
First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tool is to be replaced!
Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII
and B) out of containers, results in a risk of explosion!
Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of explosion!
Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.
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2.5 Standards for warning notices in the publication
DANGER
In the event of immediate danger.
Consequences: Death or serious injury.
Preventive measures
WARNING
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
Preventive measures
CAUTION
In the event of dangerous situations.
Consequences: Slight injury or material damage.
Preventive measures
Note: This Publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!
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2.6 General information regarding the Tolerances
and Wear Limits List
The tolerances and wear limits are intended as a guide for the examination of engine components
as well as for engine inspection and repair.
Explanation of terms for dimensions of new components
Toleranced size Designed size followed by a fit symbol (e.g. 24 H6) or by
the permissible dimensional deviation (e.g. 24 +0.013)
Basic size Designed size without fit symbol or permissible
dimensional deviation
Deviation Permissible tolerance of toleranced/basic size.
Deviation determines the upper and lower limit of the
toleranced/basic size
Clearance Difference between bore and shaft diameter when bore
diameter is greater than shaft diameter
Interference Difference between bore and shaft diameter when bore
diameter is smaller than shaft diameter
Explanation of terms for reconditioning of components
Wear limit The wear limits do not denote the max. permissible
wear for correct functioning of the component. They are
to show that the component will reach the next required
complete overhaul. The component must be replaced if
the wear limit is exceeded.
Reworking instructions If wear limits are exceeded or values are below
specification, the components concerned must be
reworked as per reworking instructions or replaced.
Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limits unless
specifically indicated. All dimensions are given in "mm" unless otherwise specified.
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2.7 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).
The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of engine components is also from the driving end, starting with No. 1.
1 KGS = Free end
2 Right side
3 KS = Driving end
4 Left side
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2.8 Tightening specifications for screws, nuts and bolts
Crankcase
Designation Torque specifications Lubricant
Stud for crankshaft bearing cap in crankcase
(to blind hole base)
80 Nm
Stud (nominal length: 347.5 mm to 348.5 mm):
Stud elongation for crankshaft bearing cap I = 1.15 mm +0.05 mm
Residual screw elongation I = 0.9 mm +0.05 mm
Newly fitted studs must be elongated before initial tightening.
Lateral socket-head screws:
1 Starting, driving end: Left side, all
screws
80 Nm
2 Starting, driving end: Right side, all
screws
80 Nm
3 Final tightening torque, left side 280 Nm +20 Nm
4 Final tightening torque, right side 280 Nm +20 Nm
Screws for oil pan made of extruded and cast aluminum.
Screw A 60 Nm +6 Nm
Screw B 27 Nm +3 Nm
Stress bolt C 27 Nm +3 Nm
Stress bolt D 27 Nm +3 Nm
Screw E 74 Nm +7 Nm
Screws for spherical-graphite cast iron oil pan
Screw A 42 Nm +4
Screw B 42 Nm +4
Screw C 74 Nm +7
Engine oil
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Crank drive
Screws for counterweight
Nominal length: 129.6 mm to 130 mm
Max. length: 132 mm
1 Pretightening torque 320 Nm +30 Nm
2 Additional angle of rotation 120 + 10
3 Checking torque 800 Nm +50 Nm
Screws for vibration damper flange 500 Nm +50 Nm
Engine oil
Screws for side plate, vibration damper 400 Nm Engine oil on thread only
Conrod screws
Nominal length: 102.6 mm to 103.2 mm
Max. elongation: 104.5 mm
1 Pretightening torque
Sequence:
a Short arm
b Long arm
240 Nm +20 Nm
2 Additional angle of rotation
Sequence:
a Short arm
b Long arm
90 + 10
3 Checking torque
Sequence:
a Short arm
b Long arm
450 Nm +20 Nm
Screws for seal carrier, free end 74 Nm +7 Nm
Graduated disc screws 21 Nm +2 Nm
Engine oil
Piston crown screws
Nominal size, incl. allowance: 49 mm
0.1 mm.
Max. length for reassembly: 49.8 mm.
0.1 mm.
1 Tighten screws diagonally and evenly. 17 Nm
2 Release screws
3 Pretightening torque 10 Nm + 10 Nm
Molykote G-N Plus
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Cylinder head
Sleeve for injector 60 Nm +6 Nm
Plug screw 60 Nm +6 Nm
Tightening sequence of screws:1 to 6
1 Tighten 25 Nm
3 Additional angle of rotation 180 +10
4 Checking torque 400 Nm
Engine oil
A Exhaust side
B Inlet side
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Valve gear
Screw camshaft gear. 100 Nm + 10 Nm
Screws for rocker shaft support
Max. shaft length: 180.8 mm
250 Nm +25 Nm
Version I: Locknut 24 A/F of valve bridge for
exhaust valve clearance adjusting screw
90 Nm +9 Nm
Version I: 24 A/F locknut of valve bridge for
inlet and valve clearance of adjusting screw
90 Nm +9 Nm
Version II: Locknut 19 A/F of valve bridge for
35 Nm +5 Nm
Version II: 19 A/F locknut of valve bridge for
35 Nm +5 Nm
Locknut on adjusting screw for valve bridge 35 Nm +5 Nm
Screw for cylinder head cover 42 Nm
Engine oil
Fuel system high pressure
Nut, high-pressure line to limiting valve 140 Nm +10 Nm
Nut, high-pressure line to injector 120 Nm +12 Nm
High-pressure accumulator to crankcase 57 Nm +6 Nm
Thrust screw for high-pressure accumulator
seal
550 Nm +50 Nm
Screw for holddown clamp at injector 100 Nm + 10 Nm
Socket-head screws of
pressure relief valve
15 Nm +2 Nm
Engine oil
High-pressure lines from pump to
high-pressure accumulator
100 Nm + 10 Nm
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Exhaust turbocharger
Designation Torque
specifications
Lubricant
Rear wall to bearing housing screws 28 Nm
Screws for turbine-side clamping segment 40 Nm Ultra-Therm MTU
Self-locking nut for clamping segment of compressor housing 15 Nm
Nut on turbine wheel
1 Pretightening torque (left-hand thread) 10 Nm
2 Angle of further rotation of shaft nut (M8) 100 5
Nut on stud of exhaust turbocharger 35 Nm +3 Nm
Stud in exhaust manifold 17 Nm +2 Nm
Ultra Ultratherm
Exhaust pipework
Screws, exhaust line to cylinder head M10
x 120
42 Nm +4 Nm
Clamps on exhaust line 15 Nm +2 Nm
Ultra-Therm MTU or Molykote
P37
Charge air cooling
Screw of connecting housing cover 31 Nm +3 Nm Engine oil
Starting equipment
Nut M12, terminal 30 30 Nm +3 Nm
Nut M12, terminal 30b 30 Nm +3 Nm
Nut M5, terminal 50 4 Nm + 10 Nm
Engine oil
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Lube-oil system
Pressure reduction valve in equipment carrier 60 Nm +20 Nm
Screw for oil pump 60 Nm +7 Nm
Nut for cooler insert 100 Nm + 10 Nm
Oil spray nozzle 21 Nm +2 Nm
Engine oil
Screw to secure cover of centrifugal oil filter,
8/12/16 V engines
6 Nm +1 Nm
Clamp to secure cover of centrifugal oil filter,
8/12/16 V engines
6 Nm +1 Nm
Battery-charging generator
Radial and axial screws of coupling 42 Nm +4 Nm
Screws, generator carrier to
equipment carrier
100 Nm + 10 Nm
Nut, coupling to generator 200 Nm +20 Nm
Screw, coupling, engine side 250 Nm +25 Nm
Screws, clamp for generator on
carrier
74 Nm +7 Nm
Screws, heat shield 21 Nm +2 Nm
Engine oil
Mounting / support
Screw (M10) for engine mounting
bracket on crankcase
42 Nm +4 Nm
350 Nm +35 Nm
Nuts for damping element on engine
carrier
580 Nm +50 Nm
Screw (M12) for engine support on
crankcase
74 Nm +7 Nm
crankcase
180 Nm + 18 Nm
Engine oil
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PTO systems, driving end and free end (coupling)
Geislinger coupling F56
4 Assembly screws 150 Nm +15 Nm
Screw M16 for coupling on flywheel
2 Additional angle of rotation 60 to 65
Screw M 16 (slotted) 180 Nm
Engine oil
Screw M 10 45 Nm Molykote 1000
Screw M 10 75 Nm Loctite 242
Dished washers Loctite 270
Geislinger coupling F56 with bearing housing
Screws for bearing housing cover 100 Nm + 10 Nm Engine oil
Diaphragm coupling, driving end, for alternator
Diaphragm coupling securing
screws
250 Nm +25 Nm pretightening
50 Nm
Securing screws for alternator
housing on flywheel housing
100 Nm + 10 Nm
Engine oil
Ksel coupling for universal shaft
Screw M 16 x 60 250 Nm +25 Nm
Screw M 18 x 40 290 Nm
Screw M 20 x 50 500 Nm +50 Nm
Screw M 22 x 55 680 Nm + 68 Nm
Socket-head screw M 22 x 50 780 Nm
Engine oil
Vulkardan-L coupling for universal shaft
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Screw M 10 x 45 42 Nm +4 Nm
Engine oil
Centa couplings CF-A-30-S for hydropump
Screws, hydropump to pump carrier
flange
74 Nm +7 Nm
Screws, pump carrier flange to
housing
40 Nm +4 Nm
Socket-head screws, coupling hub
to additional earth (taper clamp)
74 Nm +7 Nm
Engine oil
Socket-head screw, rubber element
to coupling hub
200 Nm + 10 Nm
Plug-in pin for rubber element 200 Nm + 10 Nm
Socket-head screws and plug-in
pins of coupling are provided with
INBUS PLUS adhesive on the
thread.
Monitoring, control and regulation devices
Temperature sensor PT 1000 for
Charge air
Engine coolant
Lube oil
Fuel
Intake air
Charge air coolant
15 Nm to 30 Nm
Pressure sensor for
Lube oil
Charge air
20 Nm to 45 Nm
Fuel pressure sensor after filter 20 Nm + 3 Nm
Pressure sensor for fuel high
pressure
30 Nm + 10 Nm
Pressure sensor for crankcase
pressure
20 Nm to 45 Nm
Differential pressure monitor for lube
oil
27 Nm
Engine oil
Tightening specification for setscrew and stud connections as
per works standard MTN 5008
This works standard applies to setscrews subjected to little dynamic load as per MMN 384, DIN 912, EN
24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
They do not apply to heat-proof screws in the hot component area.
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Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or
galvanized) and 10.9 (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient tot = 0.125. Precondition: Thread and mating
faces of screws and nuts must be coated in engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values
is permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
When tightening mechanically, the permitted assembly tolerance is +15 %.
Hand-tightened Machine-tightened
Thread
8.8 M
A
(Nm) 10.9 M
A
(Nm) 8.8 M
A
(Nm) 10.9 M
A
(Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = tightening torques
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Tightening torques for stress bolt connections as per works standard MTN 5007
This standard applies to stress pin bolts and stress bolts which are subjected to static and
dynamic load of strength class 10.9 and the associated nuts.
Shaft and transition dimensions as to MMN 209 standard and material and machining to MMN
389 standard (bright surface or with phosphate coating).
When tightening manually (defined tightening), an assembly tolerance of + 10% of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
The values in the tables are for manual tightening with torque wrench.
Thread without torsion protection M
A
(Nm) with torsion protection M
A
(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect shank against torsion when tightening.
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Tightening torques for plugs as per works standard MTN 5183-1
This standard applies to plugs as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN
3852, model A (sealed by sealing ring DIN 7603-Cu).
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Tightening torques M
A
are given for plugs made of steel (St) with surface protected by a phosphate coating
and oiled or galvanized. Thread and mating faces beneath heads must be coated in engine oil prior to
assembly. When tightening manually (defined tightening), an assembly tolerance of +10% of the table values
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Tightening torques for plugs DIN 908, DIN 910 and DIN 7604A (with short screwed plug)
inserted in
Thread
steel/gray cast iron M
A
(Nm)
AI alloy M
A
(Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
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Tightening torques for plugs as per DIN 7604C (with long screwed plug)
inserted in
Thread
A
(Nm)
AI alloy M
A
(Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
Tightening torques for banjo screws as per works standard MTN 5183-2
This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu
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A
are given for banjo screws made of steel (St) with surface protected by a phosphate
coating and oiled or galvanized and for banjo screws made of copperaluminum alloys.
Thread and mating faces beneath heads must be coated in engine oil prior to assembly.
Tightening torques for banjo screws made of steel
Thread
Installed in steel/gray cast iron/Al alloy M
A
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
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Tightening torques for banjo screws made of copperaluminum alloys
Thread
A
(Nm)
M10 x 1 15
M16 x 1.5 30
Tightening torques for male connector as per works standard MTN 5183-3
This standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852,
model A (Sealed by sealing ring DIN 7603-Cu)
Tightening torques MA are given for male connectors made of steel (St) with surface protected
by a phosphate coating and oiled or galvanized.
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Thread
Installed in steel/gray cast iron M
A
(Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
Tightening torques for union nut on screwed plug ISO 6149-3
1 Union nut
2 Union body
3 O-ring
4 Linear ball bearing
Union nut: When installing the linear ball bearing, the union nut must be tightened firmly by hand (noticeable
force increase), and then a further quarter rotation (90) beyond this point.
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2.9 Settings
Firing order for Series 4000 engines
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6
16V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
Direction of rotation, viewed towards driving end
Component Direction of rotation
Crankshaft left
Camshaft right
H.P. fuel pump left
Oil pump left
Engine coolant pump left
Charge air coolant pump left
(if fitted)
left
Hydrostatic pump (if available) left
Valve clearance, engine cold (20 C)
Inlet 0.20 mm
Exhaust 0.50 mm
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Valve timing with valve clearance adjusted
No. Valve position Crank angle
1 Inlet opens 42.6 before TDC
2 Inlet closes 66.6 after BDC
3 Exhaust opens 57.6 before TDC
4 Exhaust closes 30.4 after TDC
5 Overlap 73
6 Start of delivery Performance-map controlled
I Top dead center (TDC)
II Bottom dead center (BDC)
Cam and valve lift for camshaft adjustment
Inlet Exhaust
Cam lift at TDC 1.43 mm 1.43 mm
Valve lift at TDC (zero valve
clearance)
1.80 mm to 2.30 mm 1.70 mm to 2.20 mm
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2.10 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4
= mm
ft 0.3048
= m
yd 0.9144
= m
stat. mile 1.609 = km
nm
1.852 = km
yd 3 = ft
yd 36 = in
Unit B multiplied by factor = Unit A
mm
0.03937 = in
m
3.281 = ft
km 0.6215 = stat. mile
Area
in
2
645.16
= mm
2
ft
2
0.0929
= m
2
yd
2
0.8361
= m
2
stat. mile
2
2.5889 = km
2
Unit B multiplied by factor Unit A
mm
2
0.00155 = in
2
m
2
10.7643 = ft
2
m
2
1.1960 = yd
2
km
2
0.3863 stat. mile
2
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Volume
in
3
16387
= mm
3
ft
3
0.02832
= m
3
yd
3
0.7646
= m
3
gallon (US) 3.787 = dm
3
gallon (Brit.) 4.546 = dm
3
cm
3
0.06102 = in
3
m
3
35.31 = ft
3
dm
3
0.2642 = gallon (US)
dm
3
0.22 = gallon (Brit.)
Speed
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (Brit.) 1.852 = km/h
Unit B multiplied by factor = Unit B
m/s 3.281 = ft/s
km/h 0.6215 = stat. mile/h (mph)
km/h 0.54 = knot (Brit.)
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Mass
lb 0.4536 = kg
oz
28.35
= g
ton 1.016 = t
g
0.03527
= oz
kg 2.205 = lb
t 0.9843 = ton
Force
lb 0.4536 = kp
lb 4.4483 = N
kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 = N
Density
lb s
2
/ft
4
515.4 = kg/m
3
kg/m
3
0.00194 = lb s
2
/ft
4
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0
5
Torque
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
lb/sq in (psi) 703.1 = kp/m
2
(mm WS)
lb/sq in (psi) 0.06895 = bar
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m
2
atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m
2
(mm WS)
atm 1.0332 = kp/cm
2
(at)
atm 14.696 = lb/sq in
bar 14.503 = lb/sq in
Mass moment, 2nd grade
ft lb s
2
1.3563 = kg m
2
kg m
2
0.7373 = ft lb s
2
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Energy
ft lb 1.356 = J
kcal 4186.8 = J
BTU 1055 = J
CHU 1899 = J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
Power
HP (horse power) 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 = W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
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Temperature
Celsius Kelvin Fahrenheit Raumur
x C = x + 273.15 K = 9/5x + 32 F = (4/5x) R
x K = x 273. 15 C = 9/5(x 273.15) + 32 F = 4/5(x 273.15) R
xF = 5/9(x 32) C = 5/9(x 32) + 273.15
K
= 4/9(x 32) R
xR = 5/4x C = (5/4x) + 273.15 K = (9/4x) + 32 F
Fuel consumption
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km
km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
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2.11 Repairing threaded bores with threaded inserts (Heli-Coil)
Data
Thread Core hole diameter (max./min.) Twist drill diameter
M 6 6.31/6.04 6.16.26.25
M 8 8.35/8.04 8.18.28.258.3
M 8 x 1 8.32/8.04 8.18.28.258.3
M 10 10.4/10.05 10.25
M 12 12.5/12.05 12.2512.5
M 12 x 1.5 12.43/12.05 12.25
M 14 14.53/14.06 14.2514.5
M 14 x 1.5 14.43/14.05 14.25
M 15 x 2 15.3/15.2 15.25
M 16 16.53/16.06 16.2516.5
M 16 x 1.5 16.43/16.05 16.25
M 24 x 1.5 24.43/24.05 24.25
M 26 x 1.5 26.43/26.05 26.25
M 30 x 1.5 30.43/30.05 30.25
1 Snout
2 Spindle
1. Remove thread insert with suitable removal
tool from bore (left).
2. Bore core hole with suitable twist drill - see table.
3. Cut thread with special tap.
4. Do not countersink hole!
5. Mount spindle (2) and snout (1) corresponding
with thread.
6. Groove on snout must be aligned with markings on
installation tool (arrows).
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1 Spindle
2 Thread insert
7. Insert thread insert (2) into spindle (1) in
installation tool.
8. Driver journal of the thread insert must be in
groove (arrow).
9. Use spindle to turn thread insert through snout
until it is flush at front (arrow).
10. Mount installation tool on threaded hole and install
thread insert without applying pressure to spindle.
11. Insert thread insert 1/2 to 1 1/2 turns deeper than
the threaded hole surface.
12. Use screw shearer to remove driver journals up
to M 14. With threaded inserts over M14, use
pointed pliers to move driver journal up and
down and remove.
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2.12 Abbreviations
Abbrevia-
tion
Meaning Explanation
AL Alarm
ANSI American National Standards Institute
ATL Abgasturbolader Exhaust Turbocharger
BDM Backup Data Module
BR Baureihe Engine Series
CAN Controller Area Network
CPP Controllable Pitch Propeller
CR Common Rail
DIN Deutsches Institut fr Normung e. V. German Standardization Organization, at the same
time identifier of German standards (DIN = "Deutsche
Industrie-Norm")
DIS Display Unit
DL Default Lost Alarm: CAN bus failure
ECS Engine Control System
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
FLS Fluids and Lubricants Specifications MTU publication no. A01061/..
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
ICFN ISO - Continuous rating - Fuel stop power
- Net
Power specifications acc. to DIN-ISO 3046-7
IDM Interface Data Module
IMO International Maritime Organization
ISO International Organization for
Standardization
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
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Abbrevia-
tion
Meaning Explanation
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value is lower than 1st minimum limit
LOLO Low Low Alarm: Measured value is lower than 2nd minimum limit
LOP Local Operating Panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing
Unit
OT Oberer Totpunkt Top dead center (TDC()
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
UPS Unit Pump System
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SPC Spare Parts Catalog
SS Safety System Alarm initiated by safety system
SSK Schnellschlussklappe(n) Emergency Air Shutoff Flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tools Catalog
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom dead center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water Jet Waterjet drive
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Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) 49
Diesel Engine 12V 4000 R41 /
16V 4000 R41 (1)
Instructions for Major Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1.2 Maintenance schedule matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 Task Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 Engine Checking condition before a major overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3 Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.4 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.5 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.6 Engine Run-in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.7 Initial engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1 Crankcase and Externally Mounted Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1.2 Crankcase and attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.1.3 Crankcase Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.1.4 Crankcase Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1.5 Crankcase Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1.6 Crankcase Checking upper and lower cylinder liner fit . . . . . . . . . . . . . . . . . . . 107
5.1.7 Crankcase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1.8 Crankcase Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.1.9 Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.1.10 Cylinder liner Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.1.11 Cylinder liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.1.12 Cylinder liner Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.1.13 Cylinder liner Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.1.14 Cylinder liner Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.1.15 Cylinder liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.1.16 Oil pan Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.1.17 Oil pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.1.18 Oil pan Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.1.19 Oil pan Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
M020124/02E 2009-02 MTU
50 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1)
5.1.20 Oil pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG) . . . . . . . . . . . . 153
5.1.22 Engine lifting equipment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.1.23 Engine lifting equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.1.24 Engine lifting equipment Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.1.25 Engine lifting equipment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.1.26 Engine lifting equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.1.27 End housing, driving end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.1.28 End housing, driving end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.1.29 End housing, driving end Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.1.30 End housing, driving end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.1.31 End housing, driving end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.1.32 End housing KS Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.1.33 End housing, driving end Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.1.34 End housing, driving end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.1.35 Crankcase ventilation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.1.36 Crankcase ventilation Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.1.37 Crankcase ventilation Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5.1.38 Crankcase ventilation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1.39 Oil separator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.1.40 Oil separator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.1.41 Oil separator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.1.42 Crankcase ventilation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.2 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.2.1 Gearcase, free end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.2.2 Gearcase, free end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.2.3 Gearcase, free end Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5.2.4 Equipment carrier free end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.2.5 Gearcase, free end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.2.6 Gearcase, free end Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.2.7 Gearcase, free end Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.2.8 Gearcase, free end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
5.2.9 Gear train, free end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.2.10 Gear train, free end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.2.11 Gear train, free end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.2.12 Gear train, free end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.2.13 Gear train, free end Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.2.14 Gear train, free end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5.2.15 Bearing bushing of idler gear Removal and installation . . . . . . . . . . . . . . . . . . . 210
5.3 Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
5.3.1 Running gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
5.3.2 Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.3.3 Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.3.4 Crankshaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.3.5 Crankshaft - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5.3.6 Crankshaft Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.3.7 Crankshaft Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5.3.8 Crankshaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.3.9 Crankshaft Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
M020124/02E 2009-02 MTU
5.3.10 Crankshaft bearing shells - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.3.11 Crankshaft bearing bore Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5.3.12 Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5.3.13 PTO flange, driving end, flywheel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.3.14 PTO flange, driving end, flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
5.3.15 Radial-lip shaft seal, driving end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
5.3.16 Flywheel on PTO flange, driving end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 260
5.3.17 Flywheel on PTO flange, driving end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
5.3.18 Radial-lip shaft seal, driving end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.3.19 PTO flange, driving end, flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 263
5.3.20 Crankshaft PTO, Free end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
5.3.21 Vibration damper on PTO, free end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 269
5.3.22 Vibration damper on PTO, free end Disassembly . . . . . . . . . . . . . . . . . . . . . . . 272
5.3.23 Vibration damper on PTO, free end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 273
5.3.24 Vibration damper on PTO, free end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
5.3.25 Vibration damper on PTO, free end Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.3.26 Vibration damper on PTO, free end Installation . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.3.27 Piston and conrod Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.3.28 Piston and conrod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
5.3.29 Piston and conrod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.3.30 Piston Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5.3.31 Piston Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
5.3.32 Piston Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
5.3.33 Conrod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
5.3.34 Conrod Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
5.3.35 Conrod Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
5.3.36 Conrod Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
5.3.37 Conrod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5.3.38 Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
5.3.39 Piston and conrod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5.4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
5.4.1 Cylinder head and attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
5.4.2 Valve-seat turning machine for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
5.4.3 Cylinder head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
5.4.4 Cylinder head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
5.4.5 Cylinder head Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
5.4.6 Cylinder head Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
5.4.7 Cylinder head Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
5.4.8 Cylinder head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
5.4.9 Cylinder head Plug repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
5.4.10 Cylinder head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
5.4.11 Cylinder head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
5.5 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
5.5.1 Valve gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
5.5.2 Camshaft overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
5.5.3 Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
5.5.4 Camshaft Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
5.5.5 Camshaft running surfaces and swing followers Visual inspection . . . . . . . . . . 373
5.5.6 Camshaft Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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5.5.7 Camshaft Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
5.5.8 Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
5.5.9 Camshaft drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
5.5.10 Camshaft drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
5.5.11 Camshaft drive Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
5.5.12 Camshaft drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
5.5.13 Camshaft drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
5.5.14 Camshaft thrust bearing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
5.5.15 Camshaft thrust bearing Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
5.5.16 Camshaft thrust bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
5.5.17 Camshaft thrust bearing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
5.5.18 Valve drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
5.5.19 Valve drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
5.5.20 Valve drive - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5.5.21 Valve drive Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.5.22 Valve drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
5.5.23 Valve drive Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
5.5.24 Valve drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
5.5.25 Valve drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
5.5.26 Cylinder head cover Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
5.5.27 Cylinder head cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.5.28 Cylinder head cover Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
5.5.29 Cylinder head cover Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
5.5.30 Cylinder head cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
5.6 High Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
5.6.1 HP fuel system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
5.6.2 HP pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
5.6.3 HP pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
5.6.4 High-pressure pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
5.6.5 High-pressure pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
5.6.6 HP pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
5.6.7 H.P. fuel pump Control block replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
5.6.8 Injector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
5.6.9 Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
5.6.10 Fuel injector disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
5.6.11 Injector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
5.6.12 Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
5.6.13 Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
5.6.14 High-pressure line Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
5.6.15 HP fuel line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
5.6.16 HP fuel line Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
5.6.17 HP fuel line Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
5.6.18 H.P. fuel line Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
5.6.19 HP fuel line Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
5.6.20 HP fuel line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
5.6.21 H.P. fuel system Leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
5.7 Low Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
5.7.1 Fuel system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
5.7.2 Fuel delivery pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
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5.7.3 Fuel delivery pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
5.7.4 Fuel delivery pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
5.7.5 Fuel delivery pump Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
5.7.6 Fuel delivery pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
5.7.7 Fuel delivery pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
5.7.12 Fuel pipework from fuel delivery pump to fuel filter Overview . . . . . . . . . . . . . . 476
5.7.13 Fuel lines from fuel delivery pump to fuel filter Removal . . . . . . . . . . . . . . . . . . 477
5.7.14 Fuel lines from pump to filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
5.7.15 Fuel lines from fuel delivery pump to fuel filter Check . . . . . . . . . . . . . . . . . . . . 479
5.7.16 Fuel lines from fuel delivery pump to fuel filter Installation . . . . . . . . . . . . . . . . . 480
5.7.17 Fuel duplex filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
5.7.18 Fuel duplex filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
5.7.19 Fuel duplex filter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
5.7.20 Fuel filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
5.7.21 Fuel filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
5.7.22 Fuel duplex filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
5.7.23 Fuel duplex filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
5.7.24 Fuel pipework from fuel filter to HP pump Overview . . . . . . . . . . . . . . . . . . . . . 488
5.7.25 Fuel pipework from fuel filter to HP pump Removal . . . . . . . . . . . . . . . . . . . . . 489
5.7.26 Fuel pipework from fuel filter to high-pressure pump Cleaning . . . . . . . . . . . . . 490
5.7.27 Fuel pipework from fuel filter to high-pressure pump Check . . . . . . . . . . . . . . . 491
5.7.28 Fuel pipework from fuel filter to HP pump Installation . . . . . . . . . . . . . . . . . . . . 492
5.7.29 Leak-off fuel pipework Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
5.7.30 Leak-off fuel line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
5.7.31 Leak-off fuel pipework Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
5.7.32 Leak-off fuel pipework Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
5.7.33 Leak-off fuel line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
5.8 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
5.8.1 Exhaust turbochargers Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
5.8.2 Exhaust turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
5.8.3 Exhaust turbocharger Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.8.4 Exhaust turbocharger Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
5.8.5 Exhaust turbocharger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
5.8.6 Exhaust turbocharger Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
5.8.7 Exhaust turbocharger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
5.8.8 Exhaust turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
5.9 Charge-Air Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
5.9.1 Intercooler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
5.9.2 Intercooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
5.9.3 Intercooler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
5.9.4 Intercooler Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
5.9.5 Intercooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
5.10 Air Intake/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
5.10.1 Air intake / air supply Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
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5.10.2 Intake housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
5.10.3 Intake housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
5.10.4 Intake housing Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
5.10.5 Intake housing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
5.10.6 Intake housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
5.10.7 Intake air system to cylinders, left Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
5.10.8 Air supply system to cylinders, left-hand side Removal . . . . . . . . . . . . . . . . . . . 534
5.10.9 Air supply system to cylinders, left Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
5.10.10 Air supply to cylinders, left side Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
5.10.11 Air supply system to cylinders, left-hand side Installation . . . . . . . . . . . . . . . . . 537
5.10.12 Air supply system to cylinders, right Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 538
5.10.13 Air supply system to cylinders, right-hand side Removal . . . . . . . . . . . . . . . . . . 539
5.10.14 Air supply system to cylinders, right Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 540
5.10.15 Air supply to cylinders, RHS Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
5.10.16 Air supply system to cylinders, right-hand side Installation . . . . . . . . . . . . . . . . 542
5.10.17 Air pipework from turbocharger to intercooler Overview . . . . . . . . . . . . . . . . . . 543
5.10.18 Air pipework from exhaust turbocharger to intercooler Removal . . . . . . . . . . . . 547
5.10.19 Air supply from turbocharger to intercooler Cleaning . . . . . . . . . . . . . . . . . . . . . 548
5.10.20 Air ducts from turbocharger to intercooler Check . . . . . . . . . . . . . . . . . . . . . . . 549
5.10.21 Air pipework from turbocharger to intercooler Installation . . . . . . . . . . . . . . . . . 550
5.11 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
5.11.1 Exhaust system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
5.11.2 Exhaust pipework after cylinder head Overview . . . . . . . . . . . . . . . . . . . . . . . . 552
5.11.3 Exhaust pipework after cylinder head Removal . . . . . . . . . . . . . . . . . . . . . . . . . 553
5.11.4 Exhaust pipework after cylinder head Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
5.11.5 Exhaust pipework after cylinder head Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
5.11.6 Exhaust pipework after cylinder head Installation . . . . . . . . . . . . . . . . . . . . . . . 557
5.11.7 Exhaust pipework after exhaust turbocharger Overview . . . . . . . . . . . . . . . . . . 560
5.11.8 Exhaust pipework after exhaust turbocharger Removal . . . . . . . . . . . . . . . . . . 562
5.11.9 Exhaust pipework after turbocharger Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 563
5.11.10 Exhaust pipework after exhaust turbocharger Check . . . . . . . . . . . . . . . . . . . . 564
5.11.11 Exhaust pipework after exhaust turbocharger Installation . . . . . . . . . . . . . . . . . 565
5.11.12 Exhaust pipework after engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
5.11.13 Exhaust pipework after engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
5.11.14 Exhaust pipework after engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
5.11.15 Exhaust pipework after engine Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
5.11.16 Exhaust pipework after engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
5.12 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5.12.1 Electric starter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5.12.2 Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
5.12.3 Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
5.12.4 Starter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
5.12.5 Starter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
5.12.6 Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
5.12.7 Flame starting system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
5.12.8 Flame starting system Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
5.12.9 Flame starting system Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
5.12.10 Flame starting system Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
5.12.11 Flame starting system Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
M020124/02E 2009-02 MTU
5.13 Lube Oil System, Lube Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
5.13.1 Lube-oil pump with drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
5.13.2 Lube-oil pump with drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
5.13.3 Lube-oil pump with drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
5.13.4 Lube oil pump with drive Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
5.13.5 Lube-oil pump with drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
5.13.6 Lube oil pump with drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
5.13.7 Oil filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
5.13.8 Oil filter with oil filter housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
5.13.9 Oil filter housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
5.13.10 Oil filter housing Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
5.13.11 Oil filter housing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
5.13.12 Oil filter housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
5.13.13 Oil filter with oil filter housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5.13.14 Centrifugal oil filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
5.13.15 Centrifugal oil filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
5.13.16 Centrifugal oil filter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
5.13.17 Centrifugal oil filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
5.13.18 Centrifugal oil filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
5.13.19 Centrifugal oil filter - Bearing clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
5.13.20 Centrifugal oil filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
5.13.21 Centrifugal oil filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
5.13.22 Oil heat exchanger Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
5.13.23 Oil heat exchanger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
5.13.24 Oil heat exchanger Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
5.13.25 Oil heat exchanger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
5.13.26 Oil heat exchanger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
5.13.27 Oil system in crankcase Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
5.13.28 Oil system in crankcase Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
5.13.29 Oil pipework in crankcase Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
5.13.30 Oil pipework in crankcase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
5.13.31 Oil system in crankcase Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
5.13.32 Turbocharger oil supply Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
5.13.33 Turbocharger oil supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
5.13.34 Turbocharger oil supply Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
5.13.35 Turbocharger oil supply Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
5.13.36 Turbocharger oil supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
5.14 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
5.14.1 Coolant system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
5.14.2 Engine coolant pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
5.14.3 Engine coolant pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
5.14.4 Engine coolant pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
5.14.5 Engine coolant pump Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
5.14.6 Engine coolant pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
5.14.7 Engine coolant pump Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
5.14.8 Engine coolant pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
5.14.9 Engine coolant pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
5.14.10 Coolant pipework of engine coolant pump, intake side Overview . . . . . . . . . . . 667
5.14.11 Coolant pipework for engine coolant pump, intake side Removal . . . . . . . . . . . 670
M020124/02E 2009-02 MTU
5.14.12 Coolant pipework, engine coolant pump, suction side Cleaning . . . . . . . . . . . . 671
5.14.13 Coolant pipework, engine coolant pump, suction side Check . . . . . . . . . . . . . . 672
5.14.14 Coolant pipework, engine coolant pump, suction side Installation . . . . . . . . . . 673
5.14.15 Coolant pipework after cylinder Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
5.14.16 Coolant pipework after cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
5.14.17 Coolant pipework after cylinder Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
5.14.18 Coolant pipework after cylinder Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
5.14.19 Coolant pipework after cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
5.14.20 Engine coolant drain lines Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
5.14.21 Engine coolant drain lines Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
5.14.22 Engine coolant drain lines Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
5.14.23 Engine coolant drain lines Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682
5.14.24 Engine coolant drain lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
5.14.25 Engine coolant and charge air coolant ventilation Overview . . . . . . . . . . . . . . . 684
5.14.26 Engine coolant and charge-air cooling vent Removal . . . . . . . . . . . . . . . . . . . . 686
5.14.27 Ventilation, engine coolant and charge air coolant Cleaning . . . . . . . . . . . . . . . 687
5.14.28 Ventilation, engine coolant and charge air coolant Check . . . . . . . . . . . . . . . . 688
5.14.29 Engine coolant and charge-air cooling vent Installation . . . . . . . . . . . . . . . . . . . 689
5.14.30 Coolant pipework from/to exhaust turbochargers Overview . . . . . . . . . . . . . . . 690
5.14.31 Coolant pipework from/to exhaust turbochargers Removal . . . . . . . . . . . . . . . . 691
5.14.32 Coolant pipework from/to exhaust turbochargers Cleaning . . . . . . . . . . . . . . . . 692
5.14.33 Coolant pipework from/to turbochargers Check . . . . . . . . . . . . . . . . . . . . . . . . 693
5.14.34 Coolant pipework from/to exhaust turbochargers Installation . . . . . . . . . . . . . . 694
5.14.35 Charge-air coolant pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
5.14.36 Charge-air coolant pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
5.14.37 Charge-air coolant pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
5.14.38 Charge-air coolant pump Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
5.14.39 Charge-air coolant pump Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
5.14.40 Charge-air coolant pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
5.14.41 Charge-air coolant pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
5.14.42 Charge-air coolant pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
5.14.43 Coolant pipework from/to intercooler Overview . . . . . . . . . . . . . . . . . . . . . . . . . 717
5.14.44 Coolant pipework from/to intercooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . 719
5.14.45 Coolant pipework from/to intercooler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 720
5.14.46 Coolant pipework from/to intercooler Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
5.14.47 Coolant pipework from/to intercooler Installation . . . . . . . . . . . . . . . . . . . . . . . . 722
5.14.48 Coolant pipework with thermostat Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
5.14.49 Coolant pipework with thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724
5.14.50 Coolant pipework with thermostat Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
5.14.51 Coolant pipework with thermostat Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
5.14.52 Coolant pipework with thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 731
5.15 Power Supply, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
5.15.1 Battery-charging generator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
5.15.2 Battery-charging generator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
5.15.3 Battery-charging generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737
5.15.4 Battery-charging generator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738
5.15.5 Battery-charging generator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739
5.15.6 Battery-charging generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740
5.16 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
M020124/02E 2009-02 MTU
5.16.1 Engine mounting / support Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
5.16.2 Engine mounting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744
5.16.3 Engine mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
5.16.4 Engine mount Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748
5.16.5 Engine mounts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749
5.16.6 Engine mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
5.17 PTO Systems, Driving End and Free End (Coupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
5.17.1 Geislinger steel-spring coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
5.17.2 Geislinger steel-spring coupling Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 756
5.17.3 Steel-spring coupling Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757
5.17.4 Geislinger steel-spring coupling Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758
5.17.5 Geislinger steel-spring coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760
5.17.6 Geislinger steel-spring coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
5.17.7 Diaphragm coupling Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
5.17.8 Diaphragm coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
5.17.9 Diaphragm coupling Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766
5.17.10 Diaphragm coupling Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767
5.17.11 Diaphragm coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768
5.17.12 Auxiliary PTO, lateral Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772
5.17.13 Auxiliary PTO Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
5.17.14 Auxiliary PTO Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
5.17.15 Auxiliary PTO Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
5.17.16 Auxiliary PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779
5.18 Monitoring and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
5.18.1 Monitoring, control and regulation devices Overview . . . . . . . . . . . . . . . . . . . . . 783
5.18.2 Cabling and engine wiring harnesses Overview . . . . . . . . . . . . . . . . . . . . . . . . 784
5.18.3 Engine wiring harnesses Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788
5.18.4 Engine wiring harness Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
5.18.5 Engine wiring harness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
5.18.6 Engine wiring harnesses Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 793
5.18.7 Sensors, actuators and injectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795
5.18.8 Sensors, actuators and injectors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799
5.18.9 Sensors, actuators and injectors Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
5.18.10 Sensors, actuators and injectors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
6.1 Standard tools Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
6.2 Special tools Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
6.3 General workshop equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937
6.4 Measuring tools General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 943
6.5 Tools kits Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 948
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M020124/02E 2009-02 MTU
Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) Instructions for Major Overhaul 59
Instructions for Major
Overhaul
M020124/02E 2009-02 MTU
60 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) Instructions for Major Overhaul
M020124/02E 2009-02 MTU
Maintenance Schedule 12V 4000 R41 / 16V 4000 R41 61
3 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41
3.1 Maintenance
3.1.1 Preface
MTU maintenance concept
The maintenance system for MTU products is based on a preventive maintenance concept. Preventive maintenance
makes possible advance operational planning and ensures high operational availability.
The maintenance schedule is based on the load profile/load factor specified below. The intervals at
which maintenance work is to be performed and the scope of the inspection and maintenance activities
described are based on experience of average use and serve only as a guide. Additional maintenance
work and/or adaptation of maintenance intervals may prove necessary for special applications and technical
requirements. Maintenance personnel charged with carrying out maintenance work must be appropriately
qualified depending on the complexity of the task concerned. The various stages QL1 to QL4 correspond
to the scope of training offered by MTU and the tools included in the kits:
QL1: Operational monitoring and maintenance work which may be performed without disas-
sembling the engine when it is out of operation.
QL3: Maintenance work requiring partial disassembly of the engine.
QL4: Maintenance work requiring complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. The maintenance
services must then be continued in accordance with specified intervals.
The Task numbers stated in the action list identify the various maintenance activities. They serve as a reference
for the scope of parts needed and also appear on the labels of the corresponding spare parts.
Notes on maintenance
Fluids and lubricants specifications, maintenance and replacement interval guidelines and the list of recommended
fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications A001061 and in the fluids
and lubricants specifications of the component manufacturers. They are therefore not listed in the maintenance
schedule (exception: deviations from the Fluids and Lubricants Specifications). Use only fluids and lubricants which
conform to MTU specifications or which are approved by the respective component manufacturers.
The user/customer must perform the following maintenance tasks:
Parts made of rubber or synthetic materials shall be protected from oil, wiped clean with a dry
cloth only, and never cleaned with organic cleaning agents.
Fuel prefilter:
The maintenance interval depends on the degree of fuel contamination. Paper elements in fuel
prefilters must be replaced every 2 years at the latest (task 9998).
Battery:
Battery maintenance depends on their use and prevailing ambient conditions. Battery
manufacturers specifications shall apply.
Manufacturers specifications shall apply to the maintenance of all components not listed in this maintenance schedule.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
according to the Fluids and Lubricants Specifications, MTU Publication No. A001061.
Application group
2A Rail traction
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Load profile
Load profile table
Power 100% 90% 75% <15%
Corresponding runtime 10% 15% 15% 60%
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3.1.2 Maintenance schedule matrix
0 - 21,000 Operating hours
Operating hours [h] Item
L
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e
a
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s
D
a
i
l
y
1
,
0
0
0
2
,
0
0
0
3
,
0
0
0
4
,
0
0
0
5
,
0
0
0
6
,
0
0
0
7
,
0
0
0
8
,
0
0
0
9
,
0
0
0
1
0
,
0
0
0
1
1
,
0
0
0
1
2
,
0
0
0
1
3
,
0
0
0
1
4
,
0
0
0
1
5
,
0
0
0
1
6
,
0
0
0
1
7
,
0
0
0
1
8
,
0
0
0
1
9
,
0
0
0
2
0
,
0
0
0
2
1
,
0
0
0
Engine oil filter 2
Engine running
- x
Air filter
-
X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter
-
Valve gear
-
X
x x x x x x x x x x x x x x x x x x x x
Fuel filter 2
x x x x x x x x x x x x x x x x x x x x x
Crankcase ventilation
- x x x x x x x x x x
Fuel injectors
- x x x
Cylinder chambers
-
X X X
Air filter 2 X X X
-
X X
Component maintenance
-
X X
Cylinder head
-
X
Extended component maintenance 18
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22,000 - 30,000 Operating hours
L
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2
2
,
0
0
0
2
3
,
0
0
0
2
4
,
0
0
0
2
5
,
0
0
0
2
6
,
0
0
0
2
7
,
0
0
0
2
8
,
0
0
0
2
9
,
0
0
0
3
0
,
0
0
0
Engine oil filter 2
Engine running
-
Air filter
- x x x x x x x x x
- x x x x x x x x x
Valve gear
- x x x x x x x x x
Fuel filter 2
x x x x x x x x x
- x x x x x
Fuel injectors
- x x
Cylinder chambers
- x x
Air filter 2
x x
- x
- x
Cylinder head
- x
x
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3.1.3 Maintenance tasks
Table of maintenance tasks
Interval Qual-
ifica-
tion [hours] [years]
Item Maintenance tasks TASK
QL1 Engine oil filter Replace engine oil filter during oil change or at latest after Limit
(years) (Operating Instructions)
.
W1008
QL1 Engine operation Check engine oil level (Operating Instructions ). W0500
Visually check for leaks and general condition of engine. W0501
Check intercooler drain line (if applicable). W0502
Check maintenance indicator of air filter (Operating Instructions). W0503
m
Check telltale bores of HP fuel pump (Operating Instructions). W0504
Check relief bores of coolant pump(s) (Operating Instructions). W0505
Check for abnormal running noises, exhaust gas color (Operating
Instructions) and vibrations.
W0506
Drain water and contaminants at fuel prefilter drain cock (if applicable)
(Operating Instructions).
W0507
Check contamination indicator position of fuel prefilter (if applicable)
W0508
QL1 Centrifugal oil filter Centrifugal oil filter (if applicable): Check oil residue layer thickness,
clean and replace filter sleeve (Operating Instructions).
W1009
QL1 Fuel filter Replace fuel filter or fuel filter element (Operating Instructions). W1001
QL1 Valve gear Check valve clearance (Operating Instructions ). W1002
QL1 Belt Drive Check condition and tension of drive belt, (Operating Instructions )
replace if necessary (Operating Instructions).
W1003
QL1 Air filter Replace air filter (Operating Instructions). W1005
QL1 Fuel injectors Replace fuel injectors (Operating Instructions ). W1006
QL1 Cylinder chambers Carry out endoscopic inspection on cylinder chambers (Operating
Instructions ).
W1011
QL3 Exhaust turbocharger Overhaul exhaust turbocharger ( Page 499). W1038
QL3 Component maintenance Before starting maintenance, drain coolant and flush coolant system
( Page 67).
W2000
Check rocker arm, valve bridge, swing follower and swing follower
support for wear ( Page 396).
W2001
Clean air supply pipework ( Page 526). W2002
Clean intercooler and check for leaks ( Page 519). W2003
Replace HP fuel sensor ( Page 795). W2004
Overhaul engine coolant pump ( Page 645) and charge-air coolant
pump ( Page 695).
W2005
Check engine coolant thermostat and replace thermal actuator
( Page 723).
W2006
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Interval Qual-
ifica-
Replace charge air coolant thermostat and thermal actuator
( Page 723).
W2007
Check centrifugal oil filter (if applicable) for wear ( Page 604). W2009
Overhaul starter ( Page 572). W2010
Check vibration damper ( Page 267). W2011
Replace seals on all disassembled components. W2062
QL3 Crankcase breather Crankcase breather: Replace filter or filter element ( Page 171). W1046
QL3 Cylinder head Overhaul cylinder heads, visually check piston crowns and running
pattern of cylinder liners ( Page 322).
W1063
QL3 Fuel delivery pump Replace fuel delivery pump ( Page 466). W1051
QL4 Extended component
maintenance
Perform complete engine disassembly. Inspect engine components
acc. to assembly instructions, recondition or replace as necessary
( Page 70).
W3000
Replace all elastomer components and seals. W3001
Replace piston rings ( Page 280). W3002
Replace conrod bearings ( Page 280). W3003
Replace crankshaft bearings ( Page 213). W3004
Replace cylinder liners ( Page 132). W3005
Replace auxiliary PTO antifriction bearing ( Page 734). W3006
Replace HP fuel pump ( Page 424). W3007
Overhaul generator ( Page 734). W3042
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Task Schedules 67
4 Task Schedules
4.1 Engine Checking condition before a major overhaul
Before the engine is removed, a brief test should be conducted to assist in evaluating
its condition and running behaviour.
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Deviations from the Engine Acceptance Test Record Data found during the test run provide
valuable information for subsequent overhaul services.
Operations to be performed See
Preparations for putting into operation. (Operating Instructions)
Initial operation, start engine. (Operating Instructions)
Run engine warm.
-
Perform operational checks. (Operating Instructions)
Check operating states with fault code display, assess
discrepancies.
(Operating Instructions)
Check exhaust gas color. (Operating Instructions)
Operate engine with adjustable zero-power speed.
-
Check fuel line connections for leaks.
-
Remove cylinder head cover. (Operating Instructions)
Check valve gear lubrication.
-
Take engine oil sample. (Operating Instructions)
Install cylinder head cover. (Operating Instructions)
Check intercooler drain line for leaks. (Operating Instructions)
Analyze engine oil sample (spot test, water content,
dilution with fuel).
MTU test kit
Take engine coolant sample. (Operating Instructions)
Examine engine coolant sample. MTU test kit
Check monitoring system and ECU.
-
Shut down engine. (Operating instructions)
If installed, lower coolant level in expansion tank and
check level switch response.
(Operating instructions)
Drain engine coolant. (Operating instructions)
Drain charge air coolant. (Operating Instructions)
Fill system with cleaning solution.
-
Start engine. (Operating Instructions)
Flush cooling system.
-
Flush charge air cooling system.
-
Shut down engine. (Operating Instructions)
Perform endoscopic inspection. (Operating Instructions)
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Task Schedules 69
4.2 Engine Removal
Shut off fuel supply.

Drain engine oil at operating temperature. (Operating Instructions)
Examine oil sludge for metallic residues.

Drain engine coolant. (Operating Instructions)
Wash machinery plant (as required, without chemical
detergent).

Disconnect all connections.

Install non-fibrous plugs and blanking plates to seal all
open connections.

Release engine securing screws.

Remove engine and place on stands.

Attach engine to lifting device in accordance with
transportation regulations.
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4.3 Engine Disassembly
The sequence of the work steps stated below corresponds to practical assembly procedure.
Before disassembling the engine, it is advisable to take photographs from all sides or to make
a record of all components installed on the engine.
The exact task description must be taken from the respective functional group.
Remove PTO system.

Remove intake silencer.

Remove air intake. ( Page 529)
Mark and disconnect electric cables. ( Page 788)
Remove exhaust system after engine. ( Page 568)
Remove exhaust system after exhaust
turbocharger.
( Page 562)
Remove air pipework to intercooler. ( Page 547)
Disconnect oil supply to exhaust turbocharger. ( Page 639)
Remove exhaust turbocharger. ( Page 500)
Disconnect coolant supply to exhaust
turbocharger.
( Page 691)
Remove couplings. ( Page 765)
Remove MDEC.

Remove coolant pipework, low-temperature
circuit.
( Page 719)
Remove crankcase breather. ( Page 174)
Remove charge air pipes. ( Page 534)
Remove intercooler. ( Page 521)
Remove engine coolant ventilation and
charge-air cooling.
( Page 686)
Remove exhaust pipework. ( Page 553)
Remove coolant pipework. ( Page 675)
Remove centrifugal oil filter. ( Page 607)
Remove oil cooler. ( Page 619)
Remove thermostat housing. ( Page 724)
Remove coolant pipework, high-temperature
circuit.
( Page 647)
( Page 670)
Remove coolant pump, low-temperature circuit. ( Page 697)
Remove coolant pump, high-temperature
circuit.
( Page 647)
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Task Schedules 71
Remove auxiliary PTO ( Page 775)
Remove fuel pipework from fuel filter to HP
pump.
( Page 489)
Remove leak-off fuel line. ( Page 495)
Remove leak-off fuel monitoring system. ( Page 495)
Remove HP fuel pump. ( Page 426)
Remove fuel pump, low-temperature circuit. ( Page 467)
Remove fuel filter. ( Page 482)
Remove starter. ( Page 574)
Remove HP fuel lines with HP accumulator. ( Page 449)
Remove cylinder head covers. ( Page 419)
Remove valve drive. ( Page 400)
DM_110_WM_055050_520A
Remove fuel injector. ( Page 435)
Remove cylinder heads. ( Page 330)
Remove vibration damper. ( Page 269)
Remove coolant distribution housing. ( Page 724)
Remove flywheel with timing wheel. ( Page 255)
Disassemble crankcase. ( Page 102)
Remove engine mounts. ( Page 746)
Remove engine lifting attachment. ( Page 156)
Install crankcase in crankcase rotation device. ( Page 102)
Remove end housing, driving end. ( Page 162)
Remove oil pan. ( Page 147)
Remove gearcase, free end. ( Page 186)
Remove oil pump with drive and pressure
reducing valve.
( Page 586)
Remove piston and conrod. ( Page 282)
Remove crankshaft. ( Page 216)
Remove cylinder liners. ( Page 134)
Remove oil pipework and oil spray nozzles. ( Page 629)
Remove crankcase from crankcase rotation
device.
( Page 124)
Remove camshaft drive with timing wheel. ( Page 387)
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Replace camshaft axial alignment bearing. ( Page 394)
Remove camshaft. ( Page 370)
Remove end cover. ( Page 102)
Remove studs. ( Page 102)
Remove camshaft bearing bush. ( Page 102)
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Task Schedules 73
4.4 Engine Assembly
Clean crankcase. ( Page 105)
Check crankcase. ( Page 110)
Assemble crankcase. ( Page 124)
Install cylinder liners. ( Page 142)
Install camshaft. ( Page 379)
Install oil system in crankcase. ( Page 634)
Install crankshaft. ( Page 245)
Install gearcase, free end. ( Page 195)
Install end housing, driving end ( Page 169)
Install piston with conrod. ( Page 315)
Install lube-oil pump with drive. ( Page 591)
Install oil pan. ( Page 150)
device.
( Page 124)
Install camshaft drive. ( Page 391)
Install camshaft thrust bearing. ( Page 394)
Install main oil gallery. ( Page 124)
Install engine lifting eyes. ( Page 750)
Install cylinder heads. ( Page 364)
Install coolant distribution housing. ( Page 731)
Install leak-off fuel pipework. ( Page 498)
Install valve gear. ( Page 414)
DM_110_WM_055050_720A
Install vibration damper on PTO, free end. ( Page 276)
Install PTO flange, flywheel driving end. ( Page 263)
Install engine lifting attachment. ( Page 159)
Install fuel injector. ( Page 441)
Install cylinder head cover. ( Page 422)
Install thermostat housing. ( Page 731)
Install oil cooler. ( Page 624)
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Install HP fuel pump. ( Page 430)
Install auxiliary PTO ( Page 779)
Install crankcase ventilation. ( Page 183)
Install oil filter housing. ( Page 624)
Install centrifugal oil filter. ( Page 617)
Install HP fuel line. ( Page 459)
Install fuel delivery pump. ( Page 471)
Install fuel filter. ( Page 487)
Install fuel pipework from fuel filter to HP pump. ( Page 492)
Install MDEC.

Install coolant pump, high-temperature circuit. ( Page 665)
Install coolant pump, low-temperature circuit. ( Page 715)
Install charge air manifolds. ( Page 537)
Install starter. ( Page 578)
Install intercooler. ( Page 525)
Install coolant venting lines ( Page 689)
Install coolant pipework, high-temperature circuit. ( Page 673)
Install exhaust pipework. ( Page 557)
Install coolant pipework after cylinder. ( Page 678)
Install coolant pipework from/to intercooler. ( Page 722)
Install exhaust turbocharger. ( Page 518)
Install engine coolant drain lines. ( Page 683)
Install coolant supply to exhaust turbocharger. ( Page 694)
Install exhaust turbocharger oil supply. ( Page 642)
Install air pipework to intercooler. ( Page 550)
Install exhaust system after exhaust turbocharger. ( Page 565)
Install air intake. ( Page 532)
Install exhaust pipework after engine. ( Page 571)
Install couplings. ( Page 768)
Connect electrical lines. ( Page 793)
Install intake silencer.

Install PTO system.

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Task Schedules 75
4.5 Engine Installation
Open all connections, remove caps and rubber plugs.

Attach engine at lifting eyes only and install as per
transportation instructions.
Connect coolant lines, fuel lines and engine monitoring
system.

Fill with engine coolant. (Operating instructions)
Fill with charge-air coolant. (Operating instructions)
Change/fill with engine oil. (Operating instructions)
Align engine.

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4.6 Engine Run-in procedure
Running in engine after replacing parts
After replacing pistons, piston rings or cylinder liners, run in the engine according to the respective program.
Correct running in is decisive for the service life and operational reliability of the engine.
To destroy the braking energy, use the alternator or brake.
Power must be transmitted from the engine to the brake by means of a resilient coupling.
Adjust engine operational data
Set temperatures, fuel and intake air in accordance with the temperature values in the
MTU Acceptance Test Record. Note the following:
The coolant temperature depends on the operating range of the coolant thermostat.
The fuel temperature depends on the volume of the day tank, as long as there is no
fuel cooling system available at the test bench.
Note down operational data for power, fuel, oil, coolant, charge air and exhaust gas at every test point (time,
speed and effective power) in the MTU diesel engine factory test log under RUN IN ENGINE.
Install engine on test stand.
-
Connect engine to dynamometer or generator.
-
Connect exhaust gas, coolant and fuel lines.
-
Connect control device to MDEC, DDEC.
-
Connect sensors and measuring lines for measuring
fuel, oil, coolant, charge air and exhaust gas to the
corresponding measuring points.
-
Connect dialog unit to ECU. (Acceptance Test Record)
Fill expansion tank with coolant with 2% corrosion
inhibitor oil up to max. mark.
Fill with charge-air coolant. (Operating Instructions)
Bleed coolant lines until bubble-free coolant emerges. (Operating Instructions)
Check that fuel in service or supply tank is to
specification.
(Fluids and Lubricants Specification)
Fill oil system with engine oil. (Operating Instructions)
Prime valve gear with oil. (Operating Instructions)
Check emergency shutdown system.
-
Preheat coolant. (Operating Instructions)
Prime engine oil circuit with external pump.
-
Start engine using ECU. (Operating Instructions)
After approx. 1 minute idling operation, switch off
engine and:
Check oil level. If necessary, top up oil.
Remove valve gear cover and check valve gear
lubrication.
Start engine and check idle speed.
-
Check engine running noises. (Operating Instructions)
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Task Schedules 77
Warm up engine. (Operating Instructions)
Check coolant, oil and fuel lines for leaks. (Operating Instructions)
Run in engine in accordance with run-in program and
record measured values.
(Acceptance Test Record)
Compare values with measured values in MTU
Acceptance Test Record and evaluate.
Check and enter fuel density and color of exhaust gas.
-
Enter barometric pressure and relative air humidity in
Test Record.
Check engine for abnormal running noises and leaks.
-
Check engine monitoring.
-
Adjust speed-sensitive fuel limiter performance
according to Acceptance Test Record.
(Acceptance test record, Control value sheet)
When the run-in program is completed, run down and
switch off engine.
Cut open one oil filter and check for residues. (Operating Instructions)
Check oil level and prepare engine for measurement
of oil consumption.
-
Carry out acceptance test as per Acceptance Test
Record.
-
Enter operational data in Acceptance Test Record. (Acceptance Test Record)
After completion of acceptance test, run down engine
and switch off.
Carry out measurement of oil consumption. (Operating Instructions)
Start engine.
-
Set engine to operating power in accordance with MTU
Acceptance Test Record.
Switch off engine and carry out six start/stop
procedures.
-
Carry out engine preservation run. (Operating Instructions)
Switch off engine and disable the engine starter.
-
Drain engine oil and coolant. (Operating Instructions)
Take protective measures for sea transportation.
-
Disconnect exhaust gas, coolant, and fuel lines.
-
Disconnect control device to MDEC, DDEC.
-
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Remove sensors and measuring lines and seal
measuring points.
-
Remove engine from test stand.
-
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Task Schedules 79
4.7 Initial engine operation
Carry out services to put the engine into operation. (Operating Instructions)
Preheat engine (optional).

Carry out operational checks. (Operating Instructions)
Check monitoring system and ECU. Contact Service.
Perform test run. (Acceptance test record)
Measure intake depression (only for initial operation). Contact Service.
Measure exhaust backpressure (only for initial
operation).
Contact Service.
Perform after-shutdown service. (Operating Instructions)
For extended out-of-service period:
Carry out external preservation
Disable engine start
Seal air inlet and exhaust outlet
Carry out internal preservation (air, oil, fuel)
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Crankcase
80 Nm
screws
80 Nm
screws
80 Nm
Screw A 60 Nm +6 Nm
Screw B 27 Nm +3 Nm
Screw E 74 Nm +7 Nm
Screw A 42 Nm +4
Screw B 42 Nm +4
Screw C 74 Nm +7
Engine oil
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Task Schedules 81
Crank drive
Max. length: 132 mm
Engine oil
Conrod screws
Sequence:
a Short arm
b Long arm
240 Nm +20 Nm
Sequence:
a Short arm
b Long arm
90 + 10
3 Checking torque
Sequence:
a Short arm
b Long arm
450 Nm +20 Nm
Engine oil
Piston crown screws
0.1 mm.
0.1 mm.
2 Release screws
Molykote G-N Plus
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Cylinder head
1 Tighten 25 Nm
Engine oil
A Exhaust side
B Inlet side
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Task Schedules 83
Valve gear
250 Nm +25 Nm
90 Nm +9 Nm
90 Nm +9 Nm
35 Nm +5 Nm
35 Nm +5 Nm
Engine oil
seal
550 Nm +50 Nm
15 Nm +2 Nm
Engine oil
100 Nm + 10 Nm
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Designation Torque
specifications
Lubricant
Ultra Ultratherm
Exhaust pipework
x 120
42 Nm +4 Nm
P37
Charge air cooling
Starting equipment
Engine oil
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Task Schedules 85
Lube-oil system
Engine oil
8/12/16 V engines
6 Nm +1 Nm
8/12/16 V engines
6 Nm +1 Nm
equipment carrier
100 Nm + 10 Nm
carrier
74 Nm +7 Nm
Engine oil
Mounting / support
42 Nm +4 Nm
350 Nm +35 Nm
carrier
580 Nm +50 Nm
crankcase
74 Nm +7 Nm
crankcase
180 Nm + 18 Nm
Engine oil
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Engine oil
screws
50 Nm
100 Nm + 10 Nm
Engine oil
Screw M 16 x 60 250 Nm +25 Nm
Screw M 20 x 50 500 Nm +50 Nm
Screw M 22 x 55 680 Nm + 68 Nm
Engine oil
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Task Schedules 87
Engine oil
flange
74 Nm +7 Nm
housing
40 Nm +4 Nm
74 Nm +7 Nm
Engine oil
to coupling hub
200 Nm + 10 Nm
thread.
Charge air
Engine coolant
Lube oil
Fuel
Intake air
Charge air coolant
15 Nm to 30 Nm
Pressure sensor for
Lube oil
Charge air
20 Nm to 45 Nm
pressure
30 Nm + 10 Nm
pressure
20 Nm to 45 Nm
oil
27 Nm
Engine oil
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Thread
8.8 M
A
(Nm) 10.9 M
A
(Nm) 8.8 M
A
(Nm) 10.9 M
A
(Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
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Task Schedules 89
A
A
(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
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Task Schedules 91
A
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inserted in
Thread
A
(Nm)
AI alloy M
A
(Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
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Task Schedules 93
inserted in
Thread
A
(Nm)
AI alloy M
A
(Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
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A
Thread
A
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
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Task Schedules 95
Thread
A
(Nm)
M10 x 1 15
M16 x 1.5 30
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Thread
A
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M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
1 Union nut
2 Union body
3 O-ring
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Task Descriptions 97
5 Task Descriptions
5.1 Crankcase and Externally Mounted Components
5.1.1 Engine layout
Illustration applies analogously to 8/12/16 V 4000 G, C and R
010 Crankcase and add-on components
020 Gear train
030 Running gear
040 Cylinder head
050 Valve gear
070 Fuel system (high-pressure)
080 Fuel system (low-pressure)
100 Exhaust turbocharger
110 Intercooler
120 Air intake / air supply
140 Exhaust pipework
170 Starting equipment
180 Lube oil system
200 Engine cooling system
210 Power supply
220 Cooling air system
230 Mounting system/support
250 PTO systems, driving and free
end (couplings)
500 Monitoring, control and regulating
devices, general electr. equipment
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5.1.2 Crankcase and attachments Overview
Overview of crankcase and attachments
1 Crankcase
2 Camshaft bearing
3 Crankshaft bearings
4 Stud
5 Crankshaft alignment bearing
6 Crankshaft alignment bearing cap
7 Oil pan
8 Block
9 Nut for main bearing cap
10 Socket-head screws
11 Main bearing cap
12 Cylinder liner
13 Oil filler neck
14 Oil dipstick
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5.1.3 Crankcase Overview
Crankcase with cover
1 Crankcase
2 Block
3 Screw
4 Drain valve
5 Dowel pin
6 Cover
7 Stud
8 Plug
9 Sealing ring
10 Blanking plug
11 Screw
12 O-ring
13 Holder
14 Screw
15 O-ring
16 Screw
17 Washer
18 O-ring
19 O-ring
20 Inspection port cover
21 Gasket
22 Screw
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Crankcase
1 Crankcase
2 Main bearing cap
3 Main bearing cap
4 Stud *
5 Nut
6 Screw
7 Washer
8 End cover
9 Camshaft bearing
(*) Newly fitted studs must be elongated before initial tightening
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Oil filler neck with oil dipstick
2 Sealing ring
3 Unions
4 Oil dipstick
5 O-ring
6 Cover for oil filler neck
7 Gasket
8 Hex screw
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5.1.4 Crankcase Disassembly
Preconditions
Preparatory steps have been completed.
Special tools
Designation / Use Part No. Qty.
Hydraulic kit F6557935 1
Camshaft bearing removal device F6783824 1
Hand pump kit B80146893 1
Swivel frame F6786993 1
DANGER
Suspended load.
Danger to life!
Use appropriate lifting devices and appliances.
Never stand beneath a suspended load.
WARNING
Components have sharp edges.
Risk of injury!
Wear protective gloves.
Removing externally mounted components
1. Remove cover ( Page 99).
2. Remove guide tube ( Page 99).
3. Remove oil filler neck, (not applicable to gas engines) ( Page 99).
4. Remove inspection port cover ( Page 99).
5. Remove all seals and O-rings.
Installing crankcase in crankcase rotation device
1. Attach supports (1) for swivel frame (2) on left
and right sides of crankcase.
2. Lift crankcase with lifting device and ropes.
3. Insert crankcase in swivel frame and secure.
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Removing crankshaft bearing cap and studs
1. Remove crankshaft bearing caps ( Page 216).
Note: Remove studs only if damaged or
over-elongated. When removing, replace
studs in pairs.
2. Place installation/removal tool (arrow) on studs.
3. Remove respective studs using the
installation/removal tool.
Removing camshaft bearings
1. Cover bottom of camshaft chamber to prevent
camshaft bearings from falling into the crank drive.
2. If only one bearing is replaced, protect the next
bearing (arrow) from damage.
3. Insert jig (6) in camshaft bearing (5).
4. Fit screw (1) and retainer (2) on cylinder (4)
using nut (3).
5. Press camshaft bearing (5) out of crankcase.
6. Follow the same procedure to remove the other
camshaft bearing bushings.
Removing last camshaft bearing with flywheel
housing attached
2. Removal is the same as for removal of the
camshaft bearings, with the difference that jig (1)
is used 3. .
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Removing end cover
Note: Do not drill into end cover. Metal chippings
in the crankcase coolant chamber may
cause local overheating.
1. Using a drift and hammer, carefully knock the
edge of one side of the end cover inwards until
it tilts into the bore.
2. Use pliers to withdraw plug, taking care that end
cover does not fall into the bore.
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5.1.5 Crankcase Cleaning
Material
Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air.
Risk of injury!
Do not direct compressed-air jet at persons.
Wear protective goggles / safety mask and ear protectors.
CAUTION
Contamination of components.
Damage to component!
Observe manufacturers instructions.
Check components for special cleanness.
CAUTION
Excessive reaction time of cleaning agents on components.
Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Unsuitable cleaning tools.
Use appropriate cleaning tool.
Crankcase Cleaning
1. Use cleaner (Hakupur 312) to clean elastomer components.
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
3. Clean crankcase and all threaded bores and blow clear with compressed air.
Cleaning oil filler neck and oil dipstick
2. Blow oil filler neck and oil dipstick clear with compressed air.
3. Make sure parts are perfectly clean.
Cleaning crankshaft cover
1. Remove sealant from crankcase cover.
2. Clean oil bores thoroughly with a hole brush.
3. After cleaning, flush bores (under pressure if
possible) and blow clear with compressed air.
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Cleaning oil bores in crankcase
Note: During a major engine overhaul, or if
metal chippings have got into the engine
oil system.
1. Clean oil and coolant bores thoroughly with a
suitable hole brush. Never use a wire brush!
Cleaning crankshaft bearing cap
1. Wipe bearing shell mating faces on crankshaft
bearing cap with chamois leather.
2. Clean mating faces on crankshaft bearing cap and
crankcase and blow clear with compressed air.
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5.1.6 Crankcase Checking upper and lower cylinder liner fit
Spare parts
Crankcase
a Area I of upper and lower fits
Checking area I of upper and lower fits
1. Check area I of upper and lower fits for corrosive
pitting.
Result: If corrosive pitting is visible in area I,
machine to repair stage. To be carried out only in
workshops authorized by MTU.
2. Check area I of upper and lower fit for hollows.
Result: If hollows in area I are larger than
0.500 mm over max. 30 of the circumference,
machine to repair size. To be carried out only in
3. Check area I of lower fit for recesses.
Result: If recesses are visible in area I, machine to
repair stage. To be carried out only in workshops
authorized by MTU.
a Area II of upper and lower fits
Checking area II of upper and lower fits
1. Check area II of upper fit for corrosive pitting.
Result: If corrosive pitting in area II is larger than
0.600 mm, machine to repair stage. To be carried
out only in workshops authorized by MTU.
2. Check area II of lower fit for corrosive pitting.
Result: If corrosive pitting is visible in area II,
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Exemplary illustrations showing corrosive pitting in
upper and lower fits
1. Upper fit
2. Upper fit
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3. Lower fit
4. Lower fit
5. Lower fit
6. If the assessment of the findings should be
unclear or extreme corrosive pitting was found,
(Contact Service.).
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5.1.7 Crankcase Check
Special tools
Endoscope Y20097353 1
Bore gauge, 275-300 mm Y20010175 1
C-frame micrometer, 275-300 mm Y20002705 1
Bore gauge, 160-280 mm Y20091483 1
Bore gauge, 18-100 mm Y20091481 1
Dial gauge Y20011268 1
Depth gauge, 500 mm Y20002779 1
Material
Aqueous developer (standard check) 40004 1
Dye penetrant, red 40488 1
Penetrant remover (standard check) 40002 1
Crack detection oil (No. 63) 40475 1
Crack detection agent (UV Apelux paste 1031) 40483 1
Corrosion inhibitor (Pfinder AP 11 F) 40355 1
Spare parts
Crankshaft bearing cap
Studs for main bearing
Socket-head screws for crankshaft bearing cap
Camshaft bearing
Oil filler neck, (not applicable to gas engines)
Oil dipstick
Cover
WARNING
Heavy object.
Risk of crushing!
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WARNING
Risk of injury!
CAUTION
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Crankcase Check
Item Findings Task
Check crankcase for cracks using
surface crack-testing method.
Signs of cracks Contact Service.
Use magnetic crack-testing method
to check crankshaft bearing caps for
cracks.
Signs of cracks Replace component.
Check contact surface and upper and lower cylinder liner fits in crankcase ( Page 107).
Check crankcase top for stress
marks, damage and cavitation.
Stress marks
Damage
Cavitation
visible
To be carried out only in workshops
authorized by MTU. Rework
crankcase top.
Check main bearing studs for
damage.
Damaged Replace component.
Check socket-head screws for
lateral fixation of crankshaft bearing
cap for damage.
Check camshaft bearing and guide
bushings for wear and damage.
Damaged Replace component ( Page 124).
Check all mating and sealing faces
and fits.
Stress marks Corrective work: Smooth with
oilstone or emery cloth.
Replace
Check all threads for damage. Damaged Recut threads.
Check oil filler neck for damage (not
applicable to gas engine).
Damaged Corrective work
Replace
Check that oil dipstick fits correctly
in guide tube and check for damage.
Damaged Replace component. Make sure
that replacement oil dipstick is the
correct version.
Check cover for stress marks and
damage.
Stress marks
Damage
visible
Corrective work
Replace
Use a plastic plug to prevent
each bore from being soiled
until the crankcase has been
assembled.
Use a C-frame micrometer to
measure width of crankshaft bearing
cap at upper and lower fits. Values
( Page 116)
Values exceeded. Replace cap.
Check stud for damage; measure
length of stud. Values ( Page 116)
Damaged
Values exceeded
Replace ( Page 124)
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Checking oil bores in crankcase
Note: As part of every major overhaul or if metal
chips penetrate the engine oil system, all
oil and coolant bores must be checked
for particular cleanness using a cold light
source or endoscope.
1. Check oil supply bores for valve drive at
crankcase, sides A and B.
2. Check main oil supply bores for camshaft and
main bearing in crankcase V.
3. Check oil bores (arrow) in camshaft chamber.
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4. Check oil bores in crankshaft bearing pedestal
(rear arrow) and in main bearings (front arrow).
5. Check all coolant and oil bores for contamination
in the same manner.
6. If the crankcase is then not immediately
reassembled or put back into service:
6.1. Dry oil bores.
6.2. Preserve oil bores.
6.3. Seal oil bores air-tight with suitable plugs.
Measuring bearing cap guides
Note: Bearing cap guides not in swivel
frame (results in measuring errors).
1. Remove crankcase from swivel frame and place
on a flat surface.
2. Using a bore gauge (1), measure bearing
cap guides at upper and lower fits. Values
( Page 116).
Note: To be carried out only in workshops
authorized by MTU.
3. If values are exceeded: Machine respective
bearing cap guide to next repair size using
a boring mill.
4. Install crankcase in swivel frame.
Measuring crankshaft bearing bore
1. Install and tighten crankshaft bearing cap
according to specifications ( Page 124).
2. Adjust bore gauge.
3. Using a bore gauge (2), measure the crankshaft
bearing bore (1).
4. Record measured values in data sheet. Measuring
planes as well as values ( Page 116).
authorized by MTU.
5. If values are exceeded: Machine respective bore
to next repair size using a boring mill.
6. Mark repair stages of a crankcase main bore
with numeral punches.
7. When installing a new crankshaft bearing cap:
mark position of new crankshaft bearing cap
accordingly.
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Measuring camshaft bearing bushing bore.
1. Measure diameter of camshaft bearing bushing
bore ( B) with bore gauge. Values ( Page 116).
2. If values are exceeded: Remove camshaft bearing
bushing (2) ( Page 102).
3. After removal of camshaft bearing bushing:
Measure diameter (dia. A) of the main camshaft
bearing bore in the crankcase (1). Record
measured values in data sheet. Values
( Page 116).
authorized by MTU.
main camshaft bearing bore to next repair size
using a boring mill.
5. Mark repair stages with numeral punches.
6. Install camshaft bearing bushing ( Page 124).
Measuring crankcase bores for cylinder liners
1. Measure crankcase bore for cylinder liner in upper
and lower fits with bore gauge.
2. Record measured values in data sheet. Values
( Page 116).
authorized by MTU.
crankcase bore to next repair size using a
boring mill.
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5.1.8 Crankcase Tolerances
Crankcase bore for crankshaft
Deviation Clearance Interference Wear limit No. Designation Repair
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 171.000
H6
171.035
Trans-
verse
ovality
max. 0.050
1 171.500
H6
171.535
Trans-
verse
ovality
max. 0.050
1 Crankcase bore
for crankshaft
bearing
2 172.000
H6
0 +0.025
a
After the crankcase bore has been newly produced, it can be exceeded by 0.015 mm in the a-direction
when reinstalled.
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Crankcase bore for camshaft
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 97.000
H6
1 97.500
H6
Crankcase bore
for camshaft
bearing
2 98.000
H6
0 +0.022
0 97.080
1
Camshaft
bearing, outer
removed
1 97.580
0 +0.050
0.058 0.130
Camshaft
bearing bush
bore
installed
92.012 0 +0.052 2
Camshaft outer
92.000
e7
0.107 0.072
0.084 0.171
a
Coaxiality of left and right bearing
b Between camshaft bearing bores 1 and 2
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Top deck and cylinder liner mating face
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 562.000
1 561.700
1 Cylinder liner
mating face
2 561.400
0.150 +0.050
0 562.500 0.200 +0.200
1
2 Top deck
2
562.200 0.100 +0.100
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Crankcase bore for cylinder liner
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 196.000
H7
1 196.500
H7
Crankcase bore
upper fit
2 197.000
H7
0 +0.046
0 196.000
j6
1 196.500
j6
1
Cylinder liner
upper fit
2 197.000
j6
-0.013 +0.016
0.059 0.016 +0.060
0 189.000
H7
1 189.500
H7
Crankcase bore
lower fit
2 190.000
H7
0 +0.046
0 189.000
f6
1 189.500
f6
2
Cylinder liner
lower fit
2 190.000
f6
-0.079 -0.050
0.050 0.125 +0.060
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Stage marking see reconditioning drawing
Machine all crankcase bores to the same repair size.
Main bearing cap
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 298.000
E9
1 298.500
E9
Bearing cap bed
lower fit
2 299.000
E9
+0.110 +0.240
0 298.000
p6
1 298.500
p6
1
Main bearing
caps
lower fit
2 299.000
p6
+0.056 +0.088
0.022 0.184
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 298.000
H7
1 298.500
H7
Bearing cap bed
upper fit
2 299.000
H7
0 +0.052
0 298.000
p6
1 298.500
p6
2
Main bearing
caps
upper fit
2 299.000
p6
+0.056 +0.088
0.004 0.088
3 Screw length 348.000 0.500 +0.500
Main bearing bore
Install main bearing cap in crankcase according to installation instructions.
Measure main bearing bores:
Determine diameters a, b1 and b2 in two measuring planes and calculate the averages for a, b1 and b2.
Check bore roundness:
Possible deviations from roundness are a result of the average values for a, b1 and
b2 according to the formula: (b1+b2) /2 a
Vertical ovality greater than (b1+b2) /2 is not permissible.
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Crankcase crankshaft bore coaxiality
No. Max. permissible deviation of concentricity New Wear limit
a
left/right bearing 0.040 0.050
b 8V: from main bearing 1 to 5 0.060 0.100
c
12V: from main bearing 1 to 7 0.080 0.120
d 16V: from main bearing 1 to 9 0.120 0.140
e
f applies to collar bearing mating faces
0.100 0.120
g
applies to all bearings
0.010 0.035
h applies to all bearings, non-concave 0.010 0.012
k applies to all bearings // 0.015 // 0.018
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Crankcase camshaft bore coaxiality
a
b 8V: from camshaft bearing 1 to 5 0.060 0.100
c
12V: from camshaft bearing 1 to 7 0.080 0.120
d 16V: from camshaft bearing 1 to 9 0.120 0.140
e
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5.1.9 Crankcase Assembly
Special tools
Hydraulic screw pretensioner F6557186 2
Installation/removal tool for main bearing stud F6553646 1
Stop device for plug (main oil gallery) F6555771 1
Assembly jig for camshaft bearing F6555738 1
Assembly mandrel for end cover F30378754 1
Camshaft bearing shrink-on tool F30450446 1
Guide bushing for camshaft bearing shrink-on tool F6555763 1
Torque wrench, 20-100 Nm F30026582 1
Ratchet adapter F30027340 1
Material
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Sealing paste (Elastosil N189) 50546 1
Screw locking compound Loctite No. 270 40083 1
Engine oil
Dry compressed air
Liquid nitrogen
Spare parts
Gasket
O-ring
O-ring
End cover
Camshaft bearing
Stud
DANGER
Suspended load.
Danger to life!
DANGER
Nitrogen is liquid (at -200C).
Risk of freezing and suffocation!
Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
Ventilate working area well.
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WARNING
Risk of injury!
CAUTION
CAUTION
Contamination in blind hole.
Inspect and clean blind hole.
Installing end cover
1. End cover and crankcase bore must be free
of grease and dry.
2. Coat end cover seat with Loctite screw locking
compound.
3. Using a mandrel, drive end cover into the
crankcase bore.
4. In case of leaks or sealing surface damage, the
end cover can be swaged in after it has been
driven in with a mandrel.
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Installing camshaft bearings
1. Screw camshaft bearing stop and alignment
device (1) on to locating bore of swing-follower
shafts. Installation sequence: Start at driving end
and continue in succession towards free end.
2. Fit plastic installation mandrel (1) on assembly tool.
3. Chill camshaft bearing bushing in liquid nitrogen.
4. Fit chilled camshaft bearing bushing on assembly
tool so that the spring-loaded locating mandrel
(3) of the assembly tool engages in the oil bore
(arrow) of the camshaft bearing bushing.
5. Withdraw installation mandrel from camshaft
bearing assembly tool.
6. Check position of camshaft bearing oil bore in
assembly tool (arrowed).
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7. Use assembly tool (1) to insert camshaft bearing
bushing (2) from outside in main bore as far as
it will go. At the same time, the assembly tool
is positioned by the centering and positioning
mandrel.
8. Check that oil bores in bearing bushing and
crankcase are aligned.
Installing last camshaft bearing
1. Install camshaft bearing stop and alignment device
from outside on free end of crankcase (2) when
installing last camshaft bearing.
bushing in main camshaft bore up to stop. At the
same time, the assembly tool is positioned by the
centering and positioning mandrel.
3. Check that the oil bores in bearing bushing and
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Inserting studs for crankshaft bearing caps
1. Coat thread of stud (1) on shoulder side with
engine oil.
2. Insert stud (1) with the journal side in the threaded
bore.
3. Insert stud (1) up to stop with installation/removal
device (2) and torque wrench. Tightening torque,
see ( Page 80).
Note: Replace studs only in pairs.
4. For initial fitting of studs, carry out the following
steps:
4.1. Tighten nut up to contact.
4.2. Tighten studs with hydraulic tensioner.
Tightening method: elongation.
Hydraulic pressure: 1500 bar.
4.4. Release studs.
4.5. Tighten studs again with hydraulic tensioner.
4.6. Release studs.
Installing crankshaft bearing cap
1. Install bearing cap ( Page 245).
2. Crankcase mating face (1) for strip (driving end)
must be dry and free of grease.
3. Coat contact surface with sealing paste (arrows)
and do not forget the end sides.
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4. Align strip (1) on securing screw bores (arrows) in
crankcase (2).
5. Place strip (1) on surface coated with sealing
paste on crankcase.
6. Use socket-head screws (2) to fasten strip (1) on
crankcase (3).
7. Using a straightedge, check the alignment of the
strip to the crankcase. The strip surface must form
a single plane with the crankcase joint so that the
oil pan will fit perfectly.
Installing cover
1. Mating faces on crankcase and cover (2) must be
dry and free of grease.
2. Coat new O-ring (1) with grease and insert
in groove.
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3. Mount assembly jig for cover stop on driving end.
4. Coat mating surface (1) on crankcase with surface
sealant.
5. Coat new O-rings (arrowed) with grease and insert
in oil transfer bores.
6. Insert assembly pins (2) in the crankcase at two
diagonally opposite corner points.
7. Use lifting device to connect cover to assembly
pins and lower.
8. Align cover to assembly jig stop.
9. Tighten screws in accordance with tightening
sequence.
8V 1-18
12V 1-26
16V 1-34
20V 1-42
10. Remove assembly device.
11. Coat O-ring with grease and fit on plug (1).
12. Insert plug in oil gallery and secure with lug (2).
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Removing crankcase form swivel frame
1. Attach lifting appliance and lifting ropes to
crankcase. Make sure that lifting ropes are
tensioned evenly.
2. Release crankcase from swivel frame and lift out.
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5.1.10 Cylinder liner Overview
Overview of cylinder liner with scraper ring
1 Cylinder liner 2 Carbon scraper ring 3 Sealing ring
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Cylinder liner with scraper ring in crankcase
1 Carbon scraper ring
2 Cylinder liner
3 Crankcase
4 Sealing ring
5 Sealing ring
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5.1.11 Cylinder liner Removal
Special tools
Removal tool for carbon scraper ring F6782566 1
Removal tool for cylinder liner F6557114 1
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Removing carbon scraper ring
1. Mount removal tool (3) on cylinder liner (1).
2. Remove carbon scraper ring (2) with removal tool
(3) from cylinder liner fit (1).
3. Remove removal tool (3).
4. Remove piston and conrod ( Page 282).
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Cylinder liner Removal
1. Mark installation position of cylinder liner to
crankcase with a marker pen (arrowed).
2. Insert removal tool into cylinder liner.
3. Position removal tool at lower collar of cylinder
liner. Take care not to damage the oil spray nozzle.
4. To avoid tensioning the liner, only place fork in
position lightly.
5. Rotate the removal tool spindle until the cylinder
liner is released from the crankcase bore.
6. Remove removal tool.
7. Remove cylinder liner from crankcase.
8. Remove sealing rings from cylinder liner.
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5.1.12 Cylinder liner Cleaning
Material
WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
Avoid contact with eyes and skin.
Do not inhale vapors and smoke.
Do not eat, drink, smoke when working with cleaner.
Take measures against electrostatic charging.
WARNING
Compressed air.
Risk of injury!
CAUTION
Cylinder liner Cleaning
2. Blow out all parts with compressed air.
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5.1.13 Cylinder liner Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Material
Crack detection oil (No. 63 40475 1
Spare parts
Cylinder liner
Carbon scraper ring
WARNING
Heavy object.
Risk of crushing!
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Cylinder liner Check
Item Findings Task
Check cylinder liner with magnetic
crack testing method.
Signs of cracks Replace
Check outer wall for corrosive
pitting.
Pitting visible. Replace
Check sealing and mating faces for
wear and damage.
Stress marks
Damage
visible
Corrective work: Smooth with
oilstone.
Replace
Check carbon scraper ring for
scoring and pitting.
Scores
Pitting
visible
Replace
Check floating mount of the carbon
scraper ring in the cylinder liner.
Signs of jamming Measure cylinder liner.
Replace carbon scraper ring.
Check cylinder liner running surface
for scores and pitting.
Scores
Pitting
visible
Replace
Check reversal point of first piston
ring for wear.
Wear visible. Replace cylinder liner.
Measure cylinder liner bore with
bore gauge and dial gauge.
Measurement plane and values
( Page 139)
Values exceeded. Replace
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5.1.14 Cylinder liner Tolerances
Deviation Clearance Interference Wear limit No. Designation Stage Toler-
anced
size
Basic
size
lower
upper
min.
max.
min.
max.
0 196.000
H7
1 196.500
H7
Crankcase bore
upper fit
2 197.000
H7
0 +0.046
0 196.000
j6
1 196.500
j6
1
Cylinder liner
upper fit
2 197.000
j6
-0.013 +0.016
0.059 0.016 +0.060
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anced
size
Basic
size
lower
upper
min.
max.
min.
max.
0 189.000
H7
1 189.500
H7
Crankcase bore
lower fit
2 190.000
H7
0 +0.046
0 189.000
f6
1 189.500
f6
2
Cylinder liner
lower fit
2 190.000
f6
-0.079 -0.050
0.050 0.125 +0.060
Cylinder liner ID 170.000
H7
0 +0.040 3
Scraper ring
OD
170.000
g7
-0.054 -0.014
0.014 0.094
4 Scraper ring ID 164.000
H8
0 +0.063
5 Cylinder liner ID
- installed
165.000
H7
0 +0.040
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Cylinder liner
anced
size
Basic
size
lower
upper
min.
max.
min.
max.
0 13.800
1 14.100
1
2 14.400
0.100 0
Reconditioning instructions:
In case of cavitation at upper and/or lower fit of the crankcase bore:
Introduce next repair stage and install cylinder liner of corresponding stage.
Machine cylinder liner mating face on crankcase.
To be carried out only in workshops authorized by MTU.
Check scraper ring OD and ID when fitted.
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5.1.15 Cylinder liner Installation
Special tools
Press-in tool for cylinder liner F6787880 1
Bore gauge, 160-280 mm Y20091483 1
Micrometer, 150-175 mm Y20000326 1
Material
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
Spare parts
Sealing ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Installing cylinder liner
1. Clean cylinder liner, ensuring that the lower fit and
chamfer are dry and free of grease.
2. Coat sealing rings (2) with grease.
Note: The flat side of the sealing ring must be in
contact with the cylinder liner.
3. Fit sealing rings (2) in grooves on cylinder liner (1).
Note: Note marking when re-installing used
cylinder liners; the installation position is
irrelevant when installing new cylinder
liners.
4. Insert cylinder in the same installation position as
prior to removal in accordance with the marking on
liner and crankcase.
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5. On the opposite side, insert screws (1) of press-in
tool into threaded bores for cylinder head screws.
6. Fit pressure plate (3) on cylinder liner.
7. Rotate spindle (2) clockwise to insert cylinder liner
in crankcase bore.
Measuring cylinder liner ID
1. Adjust bore gauge and dial gauge with micrometer
to basic cylinder liner bore dimension. Value and
measurement planes ( Page 139).
2. Measure cylinder liner bore with bore gauge.
3. Record measured values in data sheet.
4. If out-of-round is measured:
4.1. Remove cylinder liner.
4.2. Remeasure cylinder liner bore and outer
diameter.
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Installing carbon scraper ring
Note: Insert carbon scraper ring after installing
piston ( Page 315).
1. Spray cylinder liner and carbon scraper ring
with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
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5.1.16 Oil pan Overview
1 Oil pan
2 Rubber profile
3 Hex bolt
4 Washer
5 Hex bolt
6 Washer
7 Plug
8 Sealing ring
9 Flange
10 Gasket
11 Hex bolt
12 Hex bolt
13 Washer
14 Suction basket
15 Hex bolt
16 Washer
17 Plug-in pipe (suction pipe)
18 O-ring
19 Connecting piece
20 Hex bolt
21 Washer
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View from free end
1 Hex bolt 2 Washer 3 Oil pan
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5.1.17 Oil pan Removal
Special tools
Eyebolts
Hook-ended chain sling (4 off)
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
Oil pan Removal
1. Install the engine in the swivel support and
rotate it 180.
2. Remove hex bolts from oil pan (3).
3. Remove plugs on end faces and install eyebolts
(2).
4. Raise oil pan (3) with hook-ended chain sling (1)
and crane and lower onto suitable support.
5. Remove flanges on end faces.
6. Remove rubber profile.
Removing suction basket
1. Remove hex bolts (5) from connecting piece (2).
2. Remove connecting piece (2) with plug-in pipe (1).
3. Remove plug-in pipe (1) from connecting piece (2).
4. Remove O-rings.
5. Remove hex bolts (4) from suction basket (3).
6. Remove suction basket (3).
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5.1.18 Oil pan Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Oil pan Cleaning
2. Thoroughly blow out oil pan and all threaded bores with compressed air.
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5.1.19 Oil pan Check
Material
Red dye penetrant for surface crack test procedure
Spare parts
Oil pan
Cover
Gasket
Suction basket
Plug-in pipe
Connector
WARNING
Heavy object.
Risk of crushing!
Clean oil pan ( Page 148).
Oil pan Check
Item Findings Task
Cracktest the oil pan using the
surface cracktesting method and red
penetrant dye.
Crack indication Recondition: Contact Service.
Replace
Check mating face of oil pan with
crankcase for surface irregularities.
Surface irregularity above 0.2 mm Recondition mating face.
Check sealing surfaces and groove
of rubber profile.
Damaged Recondition
Replace
Check suction basket for damage. Damaged Replace
Check threaded bores for ease of
movement.
Sluggish Replace thread inserts.
Check plug-in pipe, connecting
piece and cover for damage.
Damaged Recondition
Replace
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5.1.20 Oil pan Installation
Special tools
Eyebolt T80092075 4
Material
Engine oil
Surface sealant (Loctite 518) 50592 1
Express dry cleaner (Loctite 7061) 50518 1
Silicone rubber (Loctite 5970) 50773 1
Spare parts
Rubber profile
WARNING
Heavy object.
Risk of crushing!
WARNING
Heavy object.
Risk of crushing!
Installing suction basket
Note: Minimize contamination!
1. Coat O-rings with grease.
2. Insert O-rings into groove as shown in overview drawing ( Page 145).
3. Install suction basket with screws.
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Preparing oil pan for installation
1. Clean flange surfaces of oil pan, equipment
carrier and crankcase.
Note: Use a new rubber profile every time the oil
pan is installed.
2. Place rubber profile in the groove on the oil pan.
3. Coat the rubber profile with grease on the end
face of the free end (arrows).
4. Fit flanges for plug screws at both end faces.
5. Apply surface sealant to fornt cover.
6. Spray lint-free rag with express dry cleaner and
wipe off excess surface sealant on the exposed
flange faces.
7. Coat slit between equipment carrier/crankcase
with silicone rubber on both sides of the equipment
carrier (arrow), laying down a bead of approx.
5 mm.
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8. Coat slit (arrow) between strip/crankcase with
silicone rubber, laying down a bead of approx.
5 mm.
9. Screw eyebolts into bores for plugs on the oil pan.
10. Lift oil pan with lifting ropes and crane.
11. Lower oil pan onto contact surface of crankcase.
12. Align oil pan to bores in the contact surface
of crankcase.
Note: Washers for screw connections A, B and
C are different.
13. Screw in screws (1).
14. Use torque wrench to tighten oil pan screws
to the specified torque according to tightening
sequence ( Page 153).
14.1. Screw A
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque Engine oil 42 Nm +4 Nm
14.2. Screw "B
14.3. Screw "C
15. Install flanges with new gaskets.
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5.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG)
Number of cylinders Screw joint Number of screws Item
12V A (long side) 28 1 to 14
12V to 20V B (driving end side) 8
-
12V to 20V C (free end side) 10
-
Bolt oil pan to crankcase and equipment carrier alternately and in several steps.
Threaded connections for oil pan made of nodular cast iron (GGG)
A Screw
B Screw
C Screw
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5.1.22 Engine lifting equipment - Overview
Overview
1 Lifting eye 2 Cylinder head screw
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Engine lifting equipment
1 Lifting eye 2 Thrust washer 3 Cylinder head screw
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5.1.23 Engine lifting equipment Removal
Preconditions
Engine lifting equipment Removal
1. Remove cylinder head screws (2).
2. Remove cylinder head screws and thrust
washers (1).
3. Remove lifting eye (3).
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5.1.24 Engine lifting equipment Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Engine lifting equipment Cleaning
2. Blow all parts clear with compressed air.
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5.1.25 Engine lifting equipment Check
Material
Spare parts
Lifting eyebolt
Thrust washer
Cylinder head screw
Engine lifting equipment Check
Item Findings Task
Check engine lifting equipment for
damage.
Damaged Replace
Check lifting eyebolt with magnetic
crack-testing method.
Signs of cracks Replace the component with an
original spare part.
Check mating and bolt-on faces for
damage.
Damaged Corrective work: Smooth with
oilstone.
Replace
Check threads in crankcase for ease
of movement.
Sluggish Corrective work: Recut threads
Check cylinder head screws for
damage.
Damaged Replace
Measure shaft length of the cylinder
head screws with depth gauge.
Value ( Page 339)
exceeded.
Replace
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5.1.26 Engine lifting equipment Installation
Special tools
Check engine lifting equipment ( Page 158)
Installing engine lifting equipment
1. Place lifting eye (3) on cylinder head and align to
the bores for the cylinder head screws.
Note: If only cylinder head screws at lifting eye
were undone just tighten these two cylinder
head screws to specified tightening torque.
2. Screw in cylinder head screw (2) with thrust
washer (1) and use torque wrench to tighten to
specified tightening torque ( Page 80).
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5.1.27 End housing, driving end Overview
End housing with attachments
1 Flywheel housing
2 Deadcenter indicator
3 Hex screw
4 Plug screw
5 Sealing ring
6 Sealing ring
7 Adapter union
8 Hex screw
9 Hex screw
10 Conical spring washer
11 O-ring
12 Guard plate
13 Guard plate
14 Hex screw
15 Washer
16 Guard plate
17 Hex screw
18 Guard plate
19 Hex screw
20 Hex screw
21 Spacer bushing
22 O-ring
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Configuration of guide bush for end housing installation and removal
1 Support
2 Guide bush
3 Guide
4 Washer
5 Nut
6 Socket-head screw
7 Flange
8 Flange
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5.1.28 End housing, driving end Removal
Preconditions
Special tools
Bracket T80091102 1
Guide bushing F6554714 1
Support F6555724 1
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
End housing Removal
Note: The TOP mark (arrow) on the front of the
guide bushing must face up, regardless of
whether the crankcase is in the installation
position or is turned through 180 .
1. Install support (2) on guide bushing (3)
( Page 160).
2. Screw bracket (1) on to end housing and attach to
crane using a slightly tensioned rope.
3. Remove all screws for end housing on crankcase
( Page 160).
4. Remove end housing from crankcase horizontally.
5. Remove O-rings.
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5.1.29 End housing, driving end Disassembly
Special tools
Removal tool for main bearing, driving end F6557190 1
Lukas cylinder B80096717 1
Hand pump set B80146893 1
WARNING
Equipment can drop off.
Liquid is highly pressurized.
Risk of injury, knocks or crushing!
Only use specified and tested equipment.
Do not enter the danger zone.
WARNING
Heavy object.
Risk of crushing!
Remove end housing, driving end ( Page 162).
Removing main bearing from end housing
1. Cut axial groove in crankshaft bearing, leaving wall
thickness of approx. 1 mm to relieve tension in
bearing.
2. Fit special tool (1), (2) on end housing.
3. Use special tool to press bearing out of end
housing.
4. Remove remaining parts as per overview drawing
( Page 160).
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5.1.30 End housing, driving end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
End housing, driving end Cleaning
2. Thoroughly blow end housing, driving end, and all threads clear with compressed air.
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5.1.31 End housing, driving end Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Retainer 0015890321/00 1
Material
Spare parts
Crankshaft bearing
End housing, driving end
End housing, driving end Check
Item Findings Task
Use the magnetic crack-testing
method to check lifting carrier and
eyebolts for cracks.
Check dead-center indicator for
damage.
Damaged Replace deadcenter indicator.
Check mating and bolt-on faces. Stress marks Smooth with oilstone.
Check threads for damage. Damaged Recut threads.
Check crankshaft bearings for
surface condition and wear *.
Stress marks
Damage
visible
Replace crankshaft bearings.
Measure bore in end housing,
driving end. Value ( Page 166)
Value exceeded Replace end housing.
* Replace crankshaft bearings during "Extended component maintenance".
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5.1.32 End housing KS Tolerances
Deviation Clearance Interference Wear
limit
No. Designation Stage Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Flywheel housing
bore
223.000
H6
0 +0.029 1
Bearing outer ,
removed
223.263 0 +0.029
0.234 0.292
Bearing bush
bore,
bearing pressed
in
210.142 0 +0.069 2
Hub outer 210.000
g7
-0.061 -0.015
0.157 0.272
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5.1.33 End housing, driving end Assembly
Special tools
Installation tool F30378426 1
Locating device F6557153 1
Material
Liquid nitrogen
DANGER
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
Check end housing, driving end ( Page 165).
Installing main bearing in end housing
1. Place end housing on suitable surface to allow
installation of the main bearing in the correct
position.
2. Install stop (1) on rear side of end housing (2).
3. Secure stop (1) on front side of end housing
(2) using two nuts.
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4. Insert main bearing (3) in locating device (5).
5. Insert main bearing (3) and installation tool (2),
ensuring they are correctly positioned with regard
to each other (position mark/notch mark) (4).
6. Press down pins (1) and lock main bearing by
turning.
7. Chill main bearing (3) with insertion tool (2) in
liquid nitrogen.
8. Place main bearing with insertion tool (2) at end
housing (1) in 12 oclock position (arrowed).
9. Insert chilled main bearing with insertion tool (2)
up to stop in end housing (1).
10. After a brief dwell period, unlock and remove
insertion tool (2).
11. Remove stop from rear side of end housing.
12. Install support bracket on end housing.
13. Install remaining parts as per overview drawing
( Page 160).
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5.1.34 End housing, driving end Installation
Special tools
Support bracket T80091102 1
Guide sleeve F6554714 1
Support F6555724 1
Material
Fast cleaner (Loctite 7061) 50518 1
Petroleum jelly, white 40317 1
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
Assemble end housing, driving end ( Page 167).
Installing end housing, driving end
1. Using fast cleaner 7061, clean mating face
(arrowed) between end housing and crankcase.
2. Apply a uniform coating of surface sealant 518 to
the sealing surface (arrowed) and smooth.
3. Coat O-rings (1) with petroleum jelly and insert
into bores.
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Note: The illustration shows the engine rotated
through 180, i.e. the oil pan mating face
faces upwards.
4. Using fast cleaner 7061 clean mating face
(arrowed) on crankcase (1).
5. Screw guide sleeve (2) onto crankshaft end flange.
6. Install support bracket (1).
7. Position support (2) on end housing.
8. Using support bracket (1), attach end housing
to crane.
9. Position end housing on guide sleeve (3) and push
towards crankcase as far as it will go.
10. Install screws into bores, tightening them to
approx. 10 Nm.
11. Tighten two opposite screws in the inner circle of
the end housing to specified tightening torque
( Page 80).
12. Remove support (2) from end housing and install
screws. Note that the screws have different
lengths.
13. Install all screws and washers and tighten to
specified tightening torque ( Page 80). Observe
the following tightening sequence:
13.1. First tighten the screws in the inner circle of
the end housing clockwise.
13.2. Then tighten the screws in the outer circle of
14. Remove excess sealant.
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5.1.35 Crankcase ventilation Overview
Crankcase ventilation, driving end, 16V
1 Vent line
2 Vent line
3 O-ring
4 Screw
5 Rubber sleeve
6 Clamp
7 Vent line
8 O-ring
9 Screw
10 Oil separator
11 Clamp
12 Washer
13 Spacer bush
14 Screw
15 Nut
16 Bracket
17 Screw
18 Guide sleeve
19 Rubber sleeve
20 Clamp
21 Pipe
22 Nut
23 Pipe
24 Nut
25 T-piece
26 Rubber sleeve
27 Clamp
28 Pipe
29 Bracket
30 Link
31 Pipe half-clamp
32 Grommet
33 Screw
34 Pipe half-clamp
35 Pipe
36 Adapter union
37 Sealing ring
38 Flange
39 Gasket
40 Screw
41 Bracket
42 Washer
43 Screw
44 Screw
45 Grommet
46 Pipe half-clamp
47 Pipe half-clamp
48 Washer
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1 Oil separator
2 Screw
3 Clamp
4 Vent line
5 O-ring
6 Screw
7 Vent line
8 Rubber sleeve
9 Clamp
10 Vent line
11 Screw
12 Pipe
13 Nut
14 Pipe
15 Nut
16 T-piece
17 Rubber sleeve
18 Clamp
19 Vent line
20 Vent line
21 Bracket
22 Screw
23 Bracket
24 Screw
25 Pipe half-clamp
26 Grommet
27 Screw
28 Adapter union
29 Sealing ring
30 Flange
31 Gasket
32 Screw
33 Oil pipe
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Crankcase ventilation, free end, 12V, 16V
1 Oil separator
2 Bracket
3 Screw
4 Screw
5 Guide sleeve
6 Rubber sleeve
7 Clamp
8 Pipe
9 Screw
10 Clamp
11 Spacer sleeve
12 Washer
13 Spacer sleeve
14 Screw
15 Nut
16 Oil line
17 Nut
18 Oil line
19 Nut
20 Pipe half-clamp
21 Pipe half-clamp
22 Grommet
23 Screw
24 Washer
25 Washer
26 Rubber sleeve
27 Clamp
28 T-piece
29 Oil line
30 Oil line
31 Banjo screw
32 Sealing ring
33 Threaded bush
34 Sealing ring
35 Bracket
36 Spacer sleeve
37 Screw
38 Pipe half-clamp
39 Grommet
40 Screw
41 Blanking cone
42 Nut
43 Pipe half-clamp
44 Grommet
45 Screw
46 Bracket
47 Screw
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5.1.36 Crankcase ventilation Removal
Preconditions
Crankcase ventilation Removal
1. Remove lines and oil separator as per overview drawings ( Page 171).
2. After removal, seal all connections with suitable plugs.
3. Protect oil separator from damage. Even minor damage may cause oil separator failure.
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5.1.37 Crankcase ventilation Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Crankcase ventilation Cleaning
Note: Protect rubber and synthetic parts from oil and fuel, rub dry only, never clean with organic cleaning
agents.
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5.1.38 Crankcase ventilation Check
Material
Corrosion inhibitor
Spare parts
Piping
Oil separator
Clamp
Retainer
Guide sleeve
Spacer bush
WARNING
Compressed air is pressurized.
Hot testing liquid.
Risk of injury and scalding!
Pressure must not exceed 0.5 bar.
Clean crankcase ventilation ( Page 175)
Crankcase ventilation Check
Item Findings Task
Visually inspect components for
damage and wear.
Damaged Replace
Check sealing surfaces and bolt-on
faces for damage and wear.
Damaged Recondition: Smooth with
oilstone
Replace
Check thread turns smoothly. Damaged Recondition: Recut threads
Replace
Pressure-test piping for leaks with
air and corrosion inhibitor in water
bath.
Air test pressure: 0.5 bar (do
not exceed test pressure)
Water temperature min. 30 C,
max. 40 C
Leaking Recondition
Replace
Inspect piping visually. Mechanical damage
Chafing
Indentation
Replace
Check operation of oil separator. Malfunction Replace
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5.1.39 Oil separator Disassembly
Remove oil separator ( Page 174).
Oil separator variant A Disassembly
1. Undo band clamp (1).
2. Remove cover (4) and O-ring.
3. Remove filter element (2).
4. Remove O-ring (3).
5. Remove O-ring (arrow) from lower part.
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Hengst oil separator variant B Disassembly
1. Remove securing screws (2) for cover (1) with
screwdriver (Torx 30).
3. Remove aerosol element (1) from oil separator
housing (2).
4. Remove securing screws for cover (1).
5. Remove cover (1), spring (2) and O-ring.
6. Remove diaphragm (3) from oil separator housing.
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5.1.40 Oil separator Check
Spare parts
Oil separator
Clean oil separator ( Page 175).
Oil separator variant A Check
Item Findings Task
damage and wear.
Damaged Replace
oilstone
Replace
Hengst oil separator variant B Check
Item Findings Task
damage and wear.
Damaged Replace
oilstone
Replace
Replace
Pressure-test oil separator for leaks
with air in water bath.
Leaking Replace
Oil separator pressure control can only be checked when installed with engine in operation. Vacuum or
overpressure is measured (e.g. with water pressure gauge) over entire engine speed range. Values should lie
between minus 10 mbar and plus 10 mbar (100 mm water column).
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5.1.41 Oil separator Assembly
Material
Petroleum jelly, white
Spare parts
Filter element with O-ring
O-rings
Check oil separator ( Page 179).
Oil separator variant A Assembly
1. Coat O-ring (3) with petroleum jelly and insert in oil
separator housing.
2. Insert filter element (2).
3. Coat O-ring with petroleum jelly and insert in
groove provided on oil separator housing.
4. Fit cover (4).
5. Tighten band clamp (1).
6. Insert O-ring (arrow) in lower part.
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Hengst oil separator variant B Assembly
1. Coat O-ring (arrow) with petroleum jelly and insert
in groove provided on oil separator housing (3).
2. Insert diaphragm (2) in oil separator housing (3)
ensuring it is correctly positioned (curvature
facing up).
3. Fit spring (1) on diaphragm (2), ensuring spring (1)
is correctly seated at diaphragm (2).
4. Mount cover (1) on spring (2) in correct position.
5. Insert screws with screwdriver and tighten
diagonally and evenly to specified torque
( Page 80) .
groove (arrow) provided on oil separator housing
(2).
7. Insert aerosol element (1) in oil separator
housing (2), ensuring it is correctly positioned.
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8. Mount cover (1) on oil separator housing and insert
screws (2) with screwdriver and tighten diagonally
and evenly to specified torque ( Page 80) .
9. Check oil separator for leaks ( Page 179).
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5.1.42 Crankcase ventilation Installation
Material
Spare parts
Gasket
O-ring
Rubber sleeve
Clamp
Crankcase ventilation Installation
1. Remove all covers.
3. Install crankcase ventilation as per overview drawing ( Page 171).
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5.2 Gear Train
5.2.1 Gearcase, free end Overview
1 Equipment carrier
2 O-ring
3 Screw
4 Sealing ring
5 Plug screw
6 Main bearing, free end
7 Idler gear, right side
8 Idler gear, left side
9 Washer
10 Washer
11 Stud
12 Nut
13 Cover
14 Gasket
15 Stud
16 Oil pump
17 Threaded bush
18 Sealing ring
19 Plug screw
20 Screw
21 Sealing ring
22 Plug screw
23 Pipe clamp half/halves
24 Oil line
25 Gasket
26 Cover
27 Grommet
28 Pressure reduction valve
29 Sealing ring(s)
30 Banjo screw
31 Seal carrier (free end)
32 Radial-lip shaft seal
33 Axle, intermediate gear
34 O-ring
35 O-ring
36 Drain plug
37 O-ring
38 Gasket
39 Cover
40 O-ring
41 Plug screw
42 Sealing ring
43 Bearing bush
44 Sealing ring
45 Plug screw
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Arrangement of alignment tool for equipment carrier and equipment carrier cover
1 Equipment carrier
2 Alignment tool
3 TOP/OBEN mark
4 Screw
5 Guide bush
6 Screw
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5.2.2 Gearcase, free end Removal
Preconditions
Special tools
Lifting gear T80091105 1
DANGER
Suspended load.
Danger to life!
Gearcase Removal
1. Insert two eyebolts (arrows) in gearcase.
2. Use rope to hook gearcase on to crane with
light initial load.
3. Unscrew screws (1) and (2) and remove with
sealing rings.
4. Unscrew and remove screws through bores in
idlers. If screws are not visible, turn crankshaft
accordingly.
5. Mark all screws on gearcase circumference
(arrows). Note that screws differ in length.
6. Remove all screws.
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7. Loosen nuts (2) on left and right sides of crankcase
and remove with washers.
8. Carefully force gearcase (1) with rope slightly
pretensioned towards free end until it is released
from crankcase.
9. Remove O-rings.
10. Set gearcase down and protect from damage.
11. Seal openings with suitable covers.
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5.2.3 Gearcase, free end Disassembly
Special tools
Adapter B80146411 1
Lucas cylinder B80096717 1
Press-out tool F6557191 1
WARNING
WARNING
Heavy object.
Risk of crushing!
Removing crankshaft bearing from equipment carrier
1. Replace crankshaft bearing if damaged or during extended component maintenance.
2. Using press-out tool, Lukas cylinder and hand pump, force crankshaft bearing out of equipment carrier.
Removing radial-lip shaft seal from seal carrier (if fitted)
1. Place seal carrier on a suitable surface.
2. Use suitable extractor to pull out radial-lip shaft seal.
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5.2.4 Equipment carrier free end Cleaning
Material
WARNING
WARNING
Compressed air.
Risk of injury!
CAUTION
Cleaning equipment carrier, free end
1. Clean elastomer parts with cleaner (Hakupur 312).
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5.2.5 Gearcase, free end Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Material
Spare parts
Equipment carrier
Crankshaft bearing
WARNING
Heavy object.
Risk of crushing!
Gearcase, free end Check
Item Findings Task
to check gearcase for cracks.
Signs of cracks Replace gearcase.
Check crankshaft bearings for wear,
scoring and indentation.
Scores
Indentations
Visible
( Page 188)
Check threads in gearcase for ease
of movement.
Sluggish Recut threads
Check thread and shaft of hex bolts
and studs for damage.
Damaged Replace.
and fits.
Damaged Recondition with oilstone or
emery cloth.
Replace
Measure crankshaft bearing in
gearcase. Values ( Page 191)
Values exceeded. Replace crankshaft bearings.
( Page 188)
Measuring crankcase bearing bore
in gearcase. Values ( Page 191)
Values exceeded. Replace gearcase.
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5.2.6 Gearcase, free end Tolerances
Deviation Clearance Interference Wear limit No. Designation Stage Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Gearcase bore 193.000
H6
0 +0.029 1
Bearing outer
dia.
removed
193.204 0 +0.029
0.175 0.233 Interfer-
ence min.
0.150
Bearing bush
bore
Bearing press-
fitted
180.121 0 +0.069 2
Driver flange
outer dia.
not press-fitted
179.800
h7
-0.040 0
0.321 0.430 Clearance
max.
0.450
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5.2.7 Gearcase, free end Assembly
Special tools
Insertion tool F30378425 1
Installation mandrel for radial-lip shaft seal F30377680 1
Material
Denatured ethanol 40250 1
Loctite 7063 50594 1
Liquid nitrogen
Spare parts
Crankshaft bearing
Radial-lip shaft seal
Studs
DANGER
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
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Installing crankshaft bearing in equipment carrier
1. Insert eyebolts in equipment carrier.
2. Use rope to hook equipment carrier on to crane
with light initial load.
3. Lift equipment carrier and move to installation
position.
4. Place equipment carrier on a firm surface and
secure.
Note: Pay attention to Oben/Top (arrow) mark.
5. Install jig (1).
6. Clean crankshaft bearing with Loctite.
7. Insert crankshaft bearing (1) in locating device (2).
Note: Ensure that position marking on crankshaft
bearing (arrow) and notch mark on
insertion tool are aligned.
8. Insert insertion tool.
9. Lock crankshaft bearing (3) on insertion tool (2)
with tommy bars (1).
10. Chill insertion tool (2) with crankshaft bearing
(3) in liquid nitrogen.
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Note: Location specified is by means of an
asymmetrical pin guide.
11. Use insertion tool (2) to install chilled crankshaft
bearing (1) on inner side of equipment carrier
up to stop.
12. After 60 seconds, unlock and remove insertion
tool (2).
13. Check positions of oil bores on crankshaft bearing.
Installing radial-lip shaft seal in seal carrier (if
applicable)
1. Push radial-lip shaft seal with sealing lip facing
down on to installation mandrel.
2. Clean and degrease sealing face for radial-lip shaft
seal in seal carrier.
3. Coat sealing face of radial-lip oil seal with ethanol.
4. Press-fit radial-lip shaft seal with drift into seal
carrier.
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5.2.8 Gearcase, free end Installation
Special tools
Alignment tool (free end), equipment carrier F6782344 1
Guide bushing for equipment carrier F6557946 1
Eyebolt 0005800100000 1
Material
Spare parts
O-ring
Sealing ring
DANGER
Suspended load.
Danger to life!
DANGER
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
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Installing equipment carrier
1. Install idler gears and axles ( Page 207).
2. Install delivery valve ( Page 627).
3. Install pressure reduction valve ( Page 591).
4. Clean alignment tool (2) and guide bushing and
coat with engine oil.
Note: TOP/BOTTOM marking must face
upwards, independent of the position of
the crankcase.
5. Use screws (1) to install alignment tool (2) on
equipment carrier.
6. Clean tail shaft, free end.
7. Screw guide bushing with screw on to tail shaft.
8. Screw eyebolts (arrows) into equipment carrier.
with light initial tension.
10. Clean contact surface (arrowed) with Loctite 7061,
ensuring that its is free of grease and dry.
11. Coat equipment carrier sealing face with Loctite
518.
12. Coat O-rings (1) with petroleum jelly and insert into
groove on equipment carrier.
Note: Woolen thread instructions do not apply to
disassembly if not fitted.
13. Lead woolen thread (2) past and close to O-ring
grooves (1).
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14. Using crane, move equipment carrier (3) over
crankshaft guide bushing (1). Always note:
14.1. The studs (2) must be aligned.
14.2. Both idler gears and the crankshaft gear
must be aligned with each other.
14.3. In each case, position one of the round
recesses on the idler gears so that screws
can be retightened. If the holes are not
visible, rotate engine accordingly.
15. Screw in nuts and washers and tighten.
Note: Relieve load on crane ropes before
tightening nuts and screws.
16. Tighten screws in the sequence 5, 6, 3, 2, 4 and 1.
17. Insert screws (arrows) evenly and tighten.
18. Remove alignment device and guide bushing.
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19. Insert screws (1) and (2) with new sealing rings.
20. Remove ropes and eyebolts.
21. Install oil line ( Page 591).
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5.2.9 Gear train, free end Overview
Item no. Designation Number of
teeth
Circumferential backlash
(mm)
Axial clearance
(mm)
1 Gear, coolant pump,
low-temperature circuit
32 0.201 0.065 to gear 9

high-temperature circuit
32 0.201 0.065 to gear 9

3 Crankshaft gear 48

4 Camshaft gear 96 0.286 0.081 to gear 3 0.1 to 0.18
5 Gear, H.P. fuel pump 32 0.201 0.065 to gear 6

6 Idler gear 89 0.285 0.080 to gear 3 0.2 to 0.6
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teeth
(mm)
Axial clearance
(mm)
7 Gear, battery-charging generator 19 0.222 0.128 to gear 6

8 Gear, oil pump 34 0.279 0.077 to gear 9

10 Gear, hydrostatic pump 34 0.201 0.065 to gear 9

1 Coolant pump drive gear
2 Shaft
3 Idler gear
4 Crankshaft
5 Crankshaft gear
6 Gearcase, free end
7 H.P. fuel pump drive gear
9 Drive flange, free end
10 Drive gear
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5.2.10 Gear train, free end Removal
Preconditions
WARNING
Heavy object.
Risk of crushing!
Removing idler gears
1. Place equipment carrier on a clean and flat
surface.
2. Remove screws (1) and (2).
3. Insert jackscrews M8 with continuous thread in
thread (arrows) of axle (3).
4. Press off axle evenly.
Removing axles
1. Mark respective axle according to installation
position and remove from equipment carrier.
2. Remove idler gears from fit.
3. Remove bearing bushing of idler gear
( Page 210).
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5.2.11 Gear train, free end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Gear train, free end Cleaning
1. Clean idler gears and oil bores of axles with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Thoroughly clean gear train, free end, by blowing clear with compressed air.
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5.2.12 Gear train, free end Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Material
Spare parts
Idler gears
Axle
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Gear train, free end Check
Item Findings Task
to check idler gears for cracks.
Signs of cracks Replace idler gears.
Check surface quality of idler gear
tooth flanks with magnifying glass.
Damaged Replace idler gear.
Check running surface of axles,
bearing bushes in idler gears and
axial friction faces of gears for wear,
scores and stress marks.
Scores
Stress marks
visible
Replace
Check taper seat and bolt-on
surface of axles for scoring and
stress marks.
Scores
Stress marks
visible
Corrective work
Replace
Check screws for damage and
threads for ease of movement.
Damaged
Sluggish
Replace screws
Measure bearing bushing bore in
idler gear. Values ( Page 205)
Values exceeded Replace bearing bushing bore
( Page 210).
Use micrometer to measure outer
diameter of axles at running surface.
Values ( Page 205)
Values exceeded Replace axle.
Measure equipment carrier bore
of idler gear axles. Values
( Page 205)
Values exceeded Replace equipment carrier.
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5.2.13 Gear train, free end Tolerances
limit
Basic
size
lower
upper
min.
max.
min.
max.
Equipment carrier
bore
81.000
H7
0 +0.035 1
Axle outer dia. 81.000
H7
0.035 0
0 0.070 Clear-
ance
max.
0.080
Idler gear bore 80.000
H7
0 +0.030 2
Bush outer dia. 80.000
s6
+0.059 0.078
0.029 0.078
Cylinder liner ID
installed 75.000
H8
0 +0.046
removed 75.000
E6
+0.060 +0.079
3
e7
0.090 0.060
0.060 0.136
Equipment carrier
bore
75.000
P7
0.051 0.021 4
e7
0.090 0.060
0.009 0.069 Clear-
ance
max.
0.080
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limit
Basic
size
lower
upper
min.
max.
min.
max.
Equipment carrier
width
41.200 0 0.200
Idler gear width 40.700 0.100 0
0.500 0.800 Clear-
ance
max.
0.900
5
Measure equipment carrier width unclamped.
6 Crankcase
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5.2.14 Gear train, free end Installation
Special tools
Holder 0015890321/00 1
Material
Engine oil
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
Check gear train, free end ( Page 203).
Installing idler gear in equipment carrier
1. Coat bearing bushings in idler gear with engine oil.
2. Insert idler gear (2) through opening (arrow) into
equipment carrier (1), ensuring it is correctly
positioned.
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Installing axles
1. Ensure oil bores of axle (3) are perfectly clean.
2. Coat O-ring (1) and (2) with petroleum jelly.
3. Insert O-ring (2) into groove of equipment carrier
(4).
4. Fit O-ring (1) in groove in axle base.
5. Insert axles into equipment carrier. Pay attention
to fit of idler gear.
6. Press axle (3) into equipment carrier.
7. Install hex screws (1) and tighten evenly.
8. Screw in screw (2).
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Checking axial clearance and backlash
1. Install two eyebolts in equipment carrier.
2. Attach equipment carrier to crane with ropes and
tension ropes equally.
3. Position equipment carrier vertically.
4. Mount magnetic dial-gauge holder (3) with dial
gauge (2) in equipment carrier.
5. Measure axial clearance:
5.1. Place dial gauge stylus with preload on
lateral collar of idler gear (1).
5.2. Set dial gauge to zero.
5.3. Check axial play by moving idler gear back
and forth in axial direction. Axial clearance
limit values ( Page 199).
6. Measure backlash:
6.1. Position dial gauge stylus with preload on
a tooth flank of idler gear.
6.3. Move idler gear back and forth in radial
direction to check backlash.
6.4. Compare with specified values in table
( Page 199).
7. If limit values are exceeded, replace idler gears.
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5.2.15 Bearing bushing of idler gear Removal and installation
Material
Liquid nitrogen
Spare parts
Bushing
DANGER
WARNING
Component is hot.
Risk of burning!
Bearing bushing Removal
1. Clean idler gear ( Page 202)
2. Using a suitable sleeve and manual press, remove
bearing bushing (1) from idler gear (2).
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Bearing bushing Installation
1. Measure main bore (3) in idler gear (2). Values
( Page 205)
2. Place idler gear on a suitable surface. Ensure that,
when inserting the bearing bushing (1), there is
no lateral projection.
3. Cool bearing bushing in liquid nitrogen and heat
idler gear to 80 C.
4. Insert chilled bearing bushing in idler gear.
Observe distance (A) 0.35 mm 0.15 mm.
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5.3 Crank Drive
5.3.1 Running gear Overview
Running gear
1 Flywheel
2 Ring gear
3 Piston
4 Conrod
5 Crankshaft
6 Crankshaft gear, free end
7 Vibration damper
8 Crankshaft counterweight
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5.3.2 Crankshaft Overview
Crankshaft detail
1 Vibration damper
2 Crankshaft bearing, free end
4 Piston
5 Cylinder liner
6 O-ring
7 Oil spray nozzle
8 Conrod
9 Crankcase
10 Conrod screw
12 Socket-head screw
13 Stud *
14 Nuts, crankshaft bearing cap
15 Crankshaft bearing cap
16 Crankshaft gear
17 O-ring
18 Crankshaft
19 O-ring
20 Hex screw
21 Seal carrier
22 Drive flange
* New studs must be pretensioned prior to first tightening
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Crankshaft
1 Crankshaft
2 Counterweight
3 Stress bolt
4 Plug
5 Crankshaft gear
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Crankshaft with bearings
1 Crankshaft bearing, top
2 Crankshaft bearing, bottom
3 Upper alignment bearing
4 Lower alignment bearing
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5.3.3 Crankshaft Removal
Preconditions
Special tools
Crankshaft locating device F6553644 2
Removal tool for crankshaft bearing caps F6783568 1
Hydraulic set F6557936 1
High-pressure hose B80144827 1
Distributor B80144838 1
Measuring device Y4341947 1
Slide protection F6553645 2
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
Removing crankshaft bearing caps
1. Check marking (1) of the crankshaft bearing caps
in relation to the crankcase.
2. If there is no marking (1): starting at driving
end, emboss main bearing numbers making
sure they can be read from the same direction.
Height of numeral punch: 6 mm.
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3. Turn crankcase upside down in swivel frame with
oil pan mating horizontal and facing upwards.
4. Remove socket-head screws (arrows) and remove
strip (1) from crankcase (2).
5. Remove all lateral screws for crankshaft bearing
caps from crankcase.
6. Starting at 1st bearing cap (driving end), position
hydraulic pretensioner on bearing cap studs.
7. Insert hydraulic screw pretensioner by hand.
8. Connect high-pressure hoses (1) of hydraulic
pump to hydraulic pretensioner (2).
9. Position magnetic holder and dial gauges on
crankcase mating face.
10. Center both gauge tips on the measuring points.
11. Set preloaded dial gauges to zero.
12. Operate hydraulic pump and simultaneously
elongate studs by a max. 0.25 mm.
13. Use a pin to loosen crankshaft bearing cap nut.
14. Release studs.
15. Position magnetic holder, dial gauges and
hydraulic pretensioner on next bearing cap.
16. Loosen and remove all nuts in the same sequence.
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1. Use removal tool to remove crankshaft bearing caps.
2. Remove bearing shell from crankshaft bearing cap and mark.
3. Protect bearing shells from damage.
Crankshaft Removal
1. To protect the crankshaft, fit sliding protection
sleeves over studs of first and last bearings.
2. Using rope (1) and crane, lift crankshaft (2) clear
of crankcase.
3. Ensure horizontal positioning of the crankshaft
when lifting.
4. Lower crankshaft on to firm supports.
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5. Use removal jig to remove bearing shells from
bearing pedestals.
6. Mark bearing shells that point towards the driving
end with the number of the corresponding main
bearing (arrow).
7. The marking (arrow) must be made by etching or
with a permanent marker.
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5.3.4 Crankshaft Disassembly
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
Removing counterweights
Note: If counterweights are to be removed, mark
relevant counterweight in its installation
position on the crankshaft prior to removal.
1. Determine and record distance A (web to
counterweight).
2. Check that counterweights are consecutively
numbered.
3. If the numbering is not visible, punch in new
numbers.
4. Lower crankshaft onto firm assembly frame.
5. Remove screws (2) and counterweight (1).
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5.3.5 Crankshaft - Cleaning
Preconditions
Engine is stopped and starting disabled.
Material
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
Heavy object.
Damage to equipment due to falling components!
Ensure that all components are secured during removal and installation work.
WARNING
CAUTION
Crankshaft - Cleaning
2. Clean crankshaft and all threads with compressed air.
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5.3.6 Crankshaft Check
Special tools
DynaMIC hardness tester Y20506341 1
Retainer 0015890321/00 1
Bore gauge, 100-160 mm Y20091482 1
Material
Spare parts
Crankshaft
Counterweight
Screw
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
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Crankshaft Check
Item Findings Task
Check mating faces of
counterweights for wear.
Wear visible Smooth with oilstone.
Use micrometer to measure
diameter and roundness of main
bearing journals and crankpins.
Record measured values in data
sheet. Values ( Page 226)
Values fallen short of. Corrective work: To be carried out
only in workshops authorized by
MTU.
Check crankshaft counterweight
with magnetic crack-testing method
for cracks.
Signs of cracks Replace crankshaft counterweight
( Page 220).
Check crankshaft gear for stress
marks.
Stress marks visible Corrective work
Replace: To be carried out only
in workshops authorized by
MTU.
Using engineers blue, check that
screw heads fit correctly.
Unevenly fitted. Level mating face.
Measure shaft length of screws with
depth gauge. Permissible shaft
length ( Page 80)
Dimension exceeded Replace screw.
with fluorescent magnetic powder to
check screws for cracks.
Signs of cracks Replace screw.
Make sure that threads are in perfect
condition.
Sluggish
Damaged
Replace screw.
Checking crankshaft for cracks
1. Install crankshaft in longitudinal direction between
jaws of test device.
2. The specified magnetic field strength of 20 A/cm
to 60 A/cm must be applied at every part of
the component.
3. Use magnetic crack-testing method to check
crankshaft for longitudinal and transverse cracks.
Also check the oil and journal bores as well as the
mating faces on counterweights and threaded
bores.
Result: If there are signs of cracks, replace
crankshaft.
4. After crack-testing, demagnetize crankshaft. A
residual field strength of 2.5 A/cm to 4 A/cm
must not be exceeded.
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Checking crankshaft journal and taper
1. Check taper surfaces (arrows) for scoring and
damage.
2. Remove minor scoring and damage by polishing
with emery cloth.
3. Recondition taper: To be carried out only in
Checking hardness of journals
Note: Check hardness of all journals when
not installed.
1. Check hardness of all journals using the DynaMIC
tester or other suitable hardness tester. Required
hardness: 49 HRC to 53 HRC.
2. Check hardness of each journal at four points at
90 intervals around circumference.
Result: If values are fallen short of, contact
Service.
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0
0
0
0
0
0
8
5
5
0
0
8
Checking concentricity of crankshaft
1. Place crankshaft on rollers in main journals on main bearing.
Main bearings 1 and 5 for 8 V
2. Use adjustable measuring holder and dial gauge to check bearing journals for concentricity.
3. If wear on circumference of journal is irregular, measure at transition from cylindrical section of journal to
radius. Values ( Page 226).
Result: If measured values deviate: Recondition crankshaft only in workshops authorized by MTU.
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5.3.7 Crankshaft Tolerances
Crankshaft bearing
Deviation Clearance Interference No. Designation Stage Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
0 171.000 H6 171.035
Trans-
verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
ovality
max. 0.050
1 Crankcase bore
for crankshaft
bearing
2 172.000 H6
0 +0.025
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Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
0 - 0 160.120
0 - 1 159.620
0 - 2 159.120
0 - 3 158.620
1 - 0 160.120
1 - 1 159.620
1 - 2 159.120
Alignment and
crankshaft
bearing
installed
1 - 3 158.620
0 +0.054 Trans-
verse
ovality
max. 0.050
0 - 0 160.000 h6 159.970
0 - 1 159.500 h6 159.470
0 - 2 159.000 h6 158.970
0 - 3 158.500 h6 158.470
1 - 0 160.000 h6 159.970
1 - 1 159.500 h6 159.470
1 - 2 159.000 h6 158.970
2
Main bearing
1 - 3 158.500 h6
0.025 0
0.120 0.199
158.470
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Conrod bearings
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Conrod bore 126.000
H6
0 +0.025
0 - 0 117.082
0 - 1 116.882
0 - 2 116.682
Conrod bearing
bore
Conrod bearing
installed
0 - 3 116.482
0 +0.048
0 - 0 117.000 h6
0 - 1 116.800 h6
0 - 2 116.600 h6
2
Conrod journal
0 - 3 116.400 h6
0.022 0
0.082 0.152
Crankpin length 97.500 0.100 +0.100 3
Conrod width 48.600 0.100 0
0.200 0.600
0 - 0 126.400
0 - 1 126.400
0 - 2 126.400
4 Expanding
dimension
Conrod bearing
shell, upper and
lower part
0 - 3 126.400
0 +1.000
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Crankshaft bearing, alignment bearing expanding dimension
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Guide bearing, upper half
2 Guide bearing, lower half
0 - 0 171.200
0 - 1 171.200
0 - 2 171.200
0 - 3 171.200
0 +0.500
1 - 0 171.700
1 - 1 171.700
1 - 2 171.700
3 Expanding
dimension
Guide bearing,
upper and lower
part
1 - 3 171.700
0 +0.500
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Crankshaft bearing expanding dimension
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Crankshaft bearing, upper half
2 Crankshaft bearing, lower half
0 - 0 171.400
0 - 1 171.400
0 - 2 171.400
0 - 3 171.400
0 +1.000
1 - 0 171.900
1 - 1 171.900
1 - 2 171.900
3 Expanding
dimension
Crankshaft
bearing, upper
and lower part
1 - 3 171.900
0 +1.000
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Crankshaft axial play
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Crankshaft axial
play
0.200 0.600 Clear-
ance
min. 0.100
max. 0.700
2 Drive flange,
pressed on
156.000 0.010 +0.010
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Crankshaft bearing shells
Bearing shells installed and bearing caps tightened as per specification.
Measure crankshaft bearing bores:
Determine diameters a, b1 and b2 in the measuring planes 1 and 2 and calculate
the average values for a, b1 and b2.
Check roundness of crankshaft bearing bores.
b2 in the formula: (b1+b2) /2 a
Replace bearing shells if:
roundness deviation >0.040
b1 : b2 is above/below 0.040
vertical ovality a > (b1+b2) /2
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Crankshaft gear, free end
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Gear, pressed on
Crankshaft front
end to gear front
end
145.500 0.300 +0.300
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Main bearing journal concentricity
Crankshaft (8V)
Max. permissible radial runout New Wear limit
From 1st main bearing journal, driving end, to last
main bearing journal, free end (arrow)
Concentricity: 0.100
From main bearing journal to main bearing journal Concentricity: 0.050
Crankshaft (12V)
Crankshaft (16V)
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Crankshaft (20V)
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5.3.8 Crankshaft - Assembly
Special tools
Spare parts
Crankshaft gear
End cover
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
Check crankshaft ( Page 222).
Installing counterweights
1. Measure shaft lengths of counterweight screws.
Max. shaft length ( Page 80).
2. Smooth mating surface for counterweight with
oilstone.
3. The mating faces of crankshaft and counterweight
(2) must be dry and free of grease.
4. Coat threads and screw head mating face of
screws (1) with engine oil.
5. Position counterweight on crankshaft according to
markings and slightly tighten screws.
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6. Align counterweight to marking (A) and tighten
screws to specified pretightening torque
( Page 80).
7. Check that the installation position of the
counterweight matches the markings or measured
dimensions made before installation.
8. Mark screw heads.
9. Tighten screws to specified additional angle of
rotation.
10. After installing counterweights, check identification
marks on counterweights and webs.
11. Dynamically balance crankshaft. ( Page 238).
12. Starting from driving end, mark counterweights
with number punch.
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5.3.9 Crankshaft Balancing
Special tools
Master weights
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Preparatory steps
1. Prior to balancing, seal all oil bores.
2. Support crankshaft at shaft journals.
3. Depending on stroke position (free residual moment), master weights must be used for dynamic balancing to
simulate the rotating and oscillating mass of conrod and piston.
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Dynamic balancing
Crankshaft (8V) Crankshaft (12V) Crankshaft (16V) Crankshaft (20V)
Maximum operating
speed
2100 rpm 1900 rpm 2100 rpm 1900 rpm
Support crankshaft
at shaft journals
1 and 5 2 and 6 2 and 8 2 and 10
Balancing assembly
mass
463 kg 525 kg 775 kg 842 kg
Balancing speed 150 rpm 150 rpm 150 rpm 150 rpm
Permissible residual
unbalance per
compensation level
for initial balancing
135 gcm 160 gcm 200 gcm 240 gcm
unbalance per
compensation level
in other clamp or
balancing machine
(comparison)
400 gcm 480 gcm 600 gcm 720 gcm
Minimum wall
thickness around
bore
5 mm 5 mm 5 mm 5 mm
A 5 (min.)
B 10
C 32 (min.)
D 8V, 12V, 16V: 18 mm (max. bore diameter); 20V:
20 mm (max. bore diameter)
E 40 mm (max. bore depth)
Bore values at counterweights
1. To balance crankshaft remove material from
counterweights by drilling with twist drill.
2. After balancing, recheck numbers on
counterweights and renumber if necessary.
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5.3.10 Crankshaft bearing shells - Check
Remove crankshaft ( Page 216).
Crankshaft bearing shells - Check
Item Findings Task
In the case of reuse (e.g.
non-scheduled removal), check
bearing shells for surface wear,
scores, cracks, corrosion, erosion
and damage.
Wear, scores, cracks, corrosion,
erosion or damage visible
Replace
Check bearing shell butt and bearing
rear side for damage and fretting
corrosion (pitting).
Fretting corrosion visible Replace and determine cause.
Possible causes:
Insufficient screw pretension
Assembly error
Spread dimension of bearing
shell out of tolerance
Faulty bearing support bore
Measure spread dimension.
( Page 226).
Determined value exceeded Replace bearing shell.
Main bearing shells (grooved bearing), upper half
Running surface has following properties when new:
A approx. 75% slide layer
B approx. 25% intermediate layer
C 5% sputtered blocking layer
Assessment
Wear of the bearing running surfaces starts at the galvanized slide layer (a). In the event of further wear, the
difference between the intermediate layer (b) and slide layer (a) remains almost constant.
A magnifying glass is required for a more accurate assessment of the running surface
wear condition (magnification min. 5x).
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In doing so, the slide layer is visible as a dark zone and the intermediate layer as a light zone. The
following is decisive for the wear condition of the grooved bearing:
Width of intermediate layer
Width of groove
Expansion of worn surface
The grooved bearing is still functional if the slide layer is partially missing in the grooves.
During each assessment of the condition of the grooves, the running surface in the area subject to
least load (groove mostly new) should be used for comparison.
The condition of the grooved bearings is assessed in five groups:
1. Continued use
2. Wear
3. Borderline wear and levelling
4. Slide layer fatigue fractures
5. Borderline slide layer continuous fractures and empty grooves
Main bearing shell (sputtered bearing), lower half
1 Slide layer
2 Blocking layer
3 Intermediate layer
4 Protective steel shell
Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the blocking layer areas exposed.
Wear of the bearing running surfaces starts at the galvanized slide layer (1).
The use of the bearing shell is already restricted in friction area once the slide layer is reduced to 70%!
It is often difficult to differentiate between the nickel barrier and softer slide layer.
If in doubt, consult a bearing specialist.
Renew bearing shells at extended component maintenance.
Damage to bearing
Damage to bearings occurs mainly through foreign body scoring, impressions and embedding,
cavitation and corrosion, pitting, fatigue and installation faults.
Bearings showing such damage must be replaced.
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5.3.11 Crankshaft bearing bore Check
Special tools
Bore gauge, 100-160 mm Y20091482 1
Installation/removal device F6553647 1
Installation aid F6553649 1
Retainer 0015890321/00 1
Material
Engine oil
Spare parts
WARNING
Compressed air.
Risk of injury!
WARNING
Risk of injury!
Note: The crankshaft bearing bore must first be checked without and subsequently with main bearings installed.
Measure crankshaft bearing bore with main bearings installed
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Measuring bearing shells
1. Turn crankcase in assembly dolly until oil pan
mating face is horizontal and facing upwards.
2. Wipe both sides of bores for crankshaft bearing in
crankcase and bearing shells with chamois leather.
3. Check codes for repair size and journal diameter
of new shells and bearing number of used
shells. These markings must be on sides facing
the driving end.
4. Compare crankcase data sheet and crankshaft
data sheet.
5. Manually press bearing shells on crankcase side
into crankcase bore to form a positive connection.
Ensure that oil bores (arrows) in bearing shells and
6. Insert bearing shells in crankshaft bearing caps
according to markings or bearing number.
7. Position bearing shell so that bearing numbers are
aligned and facing driving end.
8. Position installation tool (1) between bearing
cap stud and rear face of shell on side where
open joint is.
9. Press bearing shell on cap side (2) against guide
bearing shell on crankcase side. Make sure that
the shell joint is closed.
10. Align bearing shells axially.
11. Install crankshaft bearing cap ( Page 245).
12. Adjust bore gauge with adjusting ring or
micrometer to reference size of bearing bore.
13. Coat running surfaces of crankshaft bearing
shells with engine oil.
14. Measure crankshaft bearing bore ID with bore
gauge.
16. Compare measured values with specifications
( Page 226).
17. If values are exceeded, recondition bearing shells
to next repair size or replace.
18. After measuring crankshaft bearing bores, if
necessary mark bearing shells according to
bearing point number.
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Checking crankshaft bearing bore without main bearing installed
2. Remove bearing shells. Protect against damage.
4. Measure crankshaft bearing bore in same way as with installed bearing shells.
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5.3.12 Crankshaft Installation
Special tools
Press-in tool F6555764 1
Alignment tool F6783003 1
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
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Installing bearing shells
Note: Top and bottom bearing shells have
different part numbers. First crankshaft
bearing on driving end is designed as an
alignment bearing.
3. Use installation/removal tool to manually insert
the bearing shells on the crankcase side in
accordance with bearing numbers in crankcase
bore to form a positive connection.
4. Check stage of main crankshaft bearing bore and
stage of bearing shells. For data, see crankcase
data sheet and crankshaft data sheet.
5. Align alignment bearing shell and remaining
bearing shells with press-in tool in crankcase
bores.
Crankshaft Installation
1. Wipe bearing surfaces on crankshaft with chamois
leather.
2. Spray running faces of bearing shells on crankcase
side with engine oil.
3. To protect crankshaft, slide locating device (1)
over studs of first bearing (2).
4. Slide protective sleeve (2) over studs on last
bearing.
5. Lift crankshaft using rope slings (1) and crane.
6. Align crankshaft horizontally and vertically with
line of bores in crankcase and gradually lower
crankshaft.
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7. Remove protective sleeves and locating device.
Note: Do not rotate the crankshaft until the axial
alignment bearing has been installed.
8. Wipe lower bearing shell and crankshaft bearing
cap with chamois leather, spray running surface
with engine oil and install.
9. Check alignment of upper and lower bearing
shells. Bearing numbers on shells must be aligned
and all numbers must face driving end.
10. Position installation tool (1) between bearing cap
stud and rear face of shell on side where joint is.
11. Compress bearing shell on cap side and press
against shell on crankcase side.
Result: The joint between the shells must be
closed.
12. Axially align bearing shells.
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Note: Crankshaft bearing caps must not be
interchanged!
2. Assign bearing cap to respective bearing
according to crankcase marking (1). If not present,
stamp numbers of main bearing (1), starting
at driving end.
3. Carefully position assigned bearing cap on
respective bearing.
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4. Tap crankshaft bearing cap lightly to move to
final position.
5. Coat threads and mating faces of studs (1) with
engine oil.
6. Turn bearing cap nuts to mating face of bearing
caps.
7. Starting with 1st bearing cap (driving end or free
end), fit support sleeve (2) of hydraulic screw
pretensioner on studs (1) of respective crankshaft
bearing cap.
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8. Turn hydraulic screw pretensioner (1) by hand
until it is in position.
9. Connect high-pressure hose of hydraulic hand
pump to hydraulic screw pretensioner.
10. Position magnetic holder with dial gauges on
crankcase mating face to measure stud elongation.
11. Position the two dial gauge tips centrally on the
respective measuring core (arrow) on the sleeve
measuring pin.
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13. Operate hydraulic hand pump and elongate studs
at the same time (max. 1.15 mm +0.05 mm), use a
pin (arrow) to fit nuts on crankshaft bearing cap.
Note: Residual elongation of studs after release:
0.9 mm +0.05 mm
14. Relieve studs, check elongation of studs.
15. If residual elongation of studs is outside tolerance,
loosen nuts, and repeat nut tightening procedure; if
necessary, replace studs.
16. Mount dial gauges with magnetic holders and
hydraulic screw pretensioner on studs of adjacent
bearing cap and follow the same procedure to fit
all remaining nuts.
17. Coat screws (arrow) with engine oil.
18. Insert screws (arrow) and use torque wrench to
tighten to specified torque ( Page 80).
19. Install strip (driving end) ( Page 124).
20. In order to avoid damage to the
crankshaft bearings, install locating device (1)
before cranking the crankshaft.
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21. Fit barring tool (2) with screws on crankshaft (1)
(free end).
22. Turn crankshaft with barring tool and check for
ease of movement.
Measuring axial play of crankshaft
Note: Measure axial play only with drive flange or
flywheel mounted.
1. Mount magnetic dial gauge holder with dial gauge
(1) on crankcase.
2. Position dial gauge tip on face of crankshaft.
3. Use pry bar to press crankshaft axially as far as
it will go.
4. Set preloaded dial gauge to zero.
5. Move crankshaft from stop to stop (arrows) and
enter measured value (axial play) on data sheet.
6. If the determined value is out of tolerance
( Page 226), remove crankshaft and determine
the cause.
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5.3.13 PTO flange, driving end, flywheel Overview
1 Flywheel
2 Graduated disc
4 Screw
6 Spring pin
7 Dished washer
8 Screw
9 O-ring
10 O-ring
11 Cover
13 Screw
14 Cover
15 O-ring
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Layout for installation/removal jig for flywheel
1 Spacer
2 Screw
3 Adjusting mandrel
4 Connection
5 Flange
6 Pressure sleeve
7 Tension spindle
8 Hydraulic nut
9 Pressure line
10 Support
11 Nut
A Reference dimension: 363 mm
B Push-on dimension: 16.7 mm
to 20 mm
C Press-fitted flush
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5.3.14 PTO flange, driving end, flywheel Removal
Special tools
ZB Installation/removal tool F0140440 1
SKF hydraulic unit 5505890163/00 1
Hand pump set 5555890063/00 1
Trestle T80091387 1
Adapter F6555788 1
Impact extractor F30377999 1
Assembly sleeve F6557134 1
DANGER
Suspended load.
Danger to life!
WARNING
Removing flywheel
1. Remove screws (2) together with washers (3).
2. Remove plug (1) from flywheel.
3. Remove screws (4).
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4. Install adapter (2) for impact extractor (3) with
screws (5).
5. Remove cover (4) from flywheel (4) with impact
extractor (3).
6. Install installation/removal tool on crankcase
journal, driving end, as shown in overview drawing
( Page 253).
7. Turn crankshaft, until fixation (1) on spacer (2)
engages in flywheel.
8. Insert tension spindle into crankshaft.
9. Measure check dimension A ( Page 253).
10. Slide pressure sleeve (2) and hydraulic nut (1) over
tension spindle and screw on nut (3) with support.
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11. Remove screw for expanding bore in flywheel.
12. Screw HP line (1) on to connection (2).
13. Connect HP line (4) of hydraulic unit to hydraulic
nut (3).
14. Set hydraulic nut (3) to initial position (zero stroke).
15. Fully tighten hydraulic nut (3) to stop, then back off
nut for a distance equal to push-on dimension
( Page 253).
16. Fill up pumps (1) and (2) with engine oil SAE 10.
17. Vent pumps (1) and (2) and line system until
bubble-free oil emerges.
18. Tighten HP line.
19. Actuate hydraulic unit (2) and to bring hydraulic
nut at minimum pressure p
2
(start of pressure
increase) to attachment with flywheel.
20. Read off maximum expansion pressure p
max
at
flywheel.
21. Actuate hand pump (1) for expanding the flywheel,
until half of the maximum expansion pressure
p
1
is reached.
22. Maintain pressure p
1
for approx. 5 minutes.
23. Increase expansion pressure gradually in steps of
0,1 x p
max
with hold times of approx. 2 minutes
until the flywheel comes clear off the crankshaft.
Do not exceed maximum expansion pressure p
max
.
24. Operate pump to maintain constant expansion
pressure.
25. Monitor pressure p
2
in hydraulic nut. The release
of the flywheel from the taper seat is indicated by
rising pressure p
2
.
26. Gradually drain oil in hydraulic nut, while at the
same time continuing to pump.
27. Relieve pumps (1) and (2).
28. Screw trestle into flywheel and attach flywheel to
crane with rope lightly pretensioned.
29. Remove HP line.
30. Remove nut, support, hydraulic nut and pressure
sleeve.
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31. Install assembly sleeve (arrow) with nut.
32. Lift flywheel through assembly sleeve (arrow)
out of end housing.
33. Place flywheel on a clean surface and secure.
34. Remove nut, assembly sleeve, flange and spacer.
35. Clean assembly surfaces on flywheel and
crankshaft.
36. Close openings using suitable covers.
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5.3.15 Radial-lip shaft seal, driving end Removal
Removing radial-lip shaft seal from end housing
1. Remove end housing, driving end ( Page 162).
2. Use a suitable extractor to extract radial-lip shaft seal from end housing. Do not damage end housing and
crankshaft.
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5.3.16 Flywheel on PTO flange, driving end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Flywheel on PTO flange, driving end Cleaning
2. Remove cleaner.
3. Thoroughly blow all threads clear with compressed air.
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5.3.17 Flywheel on PTO flange, driving end Check
Material
Spare parts
Flywheel
End cover
Coiled spring pin
WARNING
Heavy object.
Risk of crushing!
Flywheel on PTO flange, driving end Check
Item Findings Task
to check flywheel and ring gear for
cracks.
Signs of cracks Replace.
Check mating faces on flywheel for
evenness, stress marks, scoring
and indentations.
Stress marks
Scores
Indentations
visible
Corrective work
Replace
Check ring gear for wear. Signs of wear Corrective work
Replace
Check end cover for wear. Signs of wear Corrective work
Replace
Measure outer diameter (hub) of
flywheel. Value ( Page 166)
Value fallen short of. Replace flywheel.
Check thread of expanding bore. Damaged Recut thread.
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5.3.18 Radial-lip shaft seal, driving end Installation
Special tools
Material
Ethanol 40250 1
Spare parts
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
Installing radial-lip shaft seal in end housing,
driving end
Note: Install radial-lip shaft seal only in mounted
end housing, driving end.
1. Install flange with spacer on front face of crankshaft
2. Fit radial-lip shaft seal, with sealing lip facing
outwards, on press-in tool.
3. Coat sealing face of radial-lip shaft seal with
ethanol.
4. Clean and degrease locating bore for radial-lip
shaft seal in end housing, driving end.
5. Position press-in tool and secure with hand screw.
6. Use press-in tool to install radial-lip shaft seal flush
in end housing, driving end.
7. Remove press-in tool with flange from crankshaft.
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5.3.19 PTO flange, driving end, flywheel Installation
Special tools
Hand pump set 5555890063/00 1
Trestle T80091387 1
Material
Engine oil
Screw locking compound (Loctite 270) 40083 1
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
CAUTION
Incorrect installation of components and lines.
Ensure that components/lines are installed so that they are never under tension or strain.
Ensure correct installation position of components.
Check flywheel on PTO flange, driving end ( Page 261).
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Installing timing wheel
1. Attach timing wheel (2) with screws (1) to flywheel,
do not tighten.
2. Drive spring pins (arrow) into flywheel.
3. Use torque wrench to tighten screws (1) to
Pressing on flywheel
1. Prior to installation, remove all covers.
2. Clean and degrease taper surface on crankshaft
with cleaner and dry and degrease with lint-free
cloth.
3. Coat lip of radial-lip oil seal with petroleum jelly.
4. Screw in tension spindle (1) and measure
reference dimension A of tension spindle
( Page 253).
5. Install spacer (3) and flange (2) together with
screws on crankshaft face.
7. Use rope to attach flywheel to crane with rope
lightly pretensioned.
8. Use crane to insert flywheel through guide sleeve
into end housing,
9. Remove assembly sleeve (arrow).
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10. Calculate push-on distance by measuring distance
from end face of crankshaft to end face of flywheel
with depth gauge.
11. If measured value is smaller than push-on distance
B, check taper for dimensional accuracy.
12. Slide pressure sleeve and hydraulic nut (3) over
nut (3).
19. Prior to press-fitting, moisten tapers fit with
expansion fluid. In doing so, actuate hand
pump (1), until expansion fluid emerges at hub
ends.
20. Actuate hydraulic unit (2) for hydraulic nut, and
attach at installation on flywheel using minimal
pressure.
max
at
flywheel.
22. Pump in expansion fluid until expansion
pressure (p
1
) can no longer be increased (do not
exceed expansion pressure P
max
), then increase
force-on force by increasing force-on pressure (p
2
).
23. Select force-on force so that end position
(pressure bush is seated against flywheel) is
achieved in approx. 5 steps.
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24. Open valve screw on hand pump (1) to relieve
expansion pressure.
25. Maintain maximum force-on pressure for 60
minutes, to ensure that the expansion fluid is
expelled from the joint and static friction can build
up between the fixed components.
26. Unscrew HP lines.
27. Remove nut, support, hydraulic nut, pressure
sleeve and tension spindle after prescribed
soaking time.
28. Coat O-rings (8) with petroleum jelly and insert in
groove on cover (7).
29. Press cover (7) into flywheel.
30. Insert screws (6) and use torque wrench to tighten
to specified torque ( Page 80).
31. Coat O-rings (1) and (3) with petroleum jelly and
insert in groove on plug (2).
33. Coat screws (4) with Loctite 270 and screw in
together with washers (5).
35. Do not subject the press-fit connection to
operational load for at least 8 hours.
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5.3.20 Crankshaft PTO, Free end Overview
1 Adapter flange
2 O-ring
3 Screw
4 Washer
5 O-ring
6 O-ring
7 Protective cover
8 Screw
9 Washer
10 Screw
11 Sealing ring
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Arrangement of the drive flange installation/removal tool
1 Draw spindle
2 Nut
3 Support
4 Connection
5 Hydraulic nut
6 Pressure sleeve
7 Flange
8 Spacer bushing
9 Drive flange
10 Crankshaft
11 Seal carrier
12 Screw
to 77.05 mm
a Push-on travel: 15.5 mm
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5.3.21 Vibration damper on PTO, free end Removal
Preconditions
Special tools
Installation/removal tool F0140771 1
Flywheel positioning fixture F6557187 1
Adjusting mandrel F30379300 2
Hook-ended chain sling (4 off) T80090748 1
Material
Engine oil SAE 10 W
DANGER
Suspended load.
Danger to life!
WARNING
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Removing vibration damper
1. Remove protective cover.
2. Block flywheel by securing with positioning fixture
on end housing.
3. Remove screws (2), one screw is left for securing
purposes.
4. Screw in two adjusting mandrels in opposing
threaded bore of drive flange.
5. Remove remaining screws.
6. Insert two jackscrews with continuous thread
in thread (1).
7. Press off vibration damper.
8. Attach vibration damper (1) with lifting gear (3)
and support bracket to crane using a lightly
tensioned rope and remove.
9. Remove adjusting mandrels (2).
Pressing off drive flange
1. Screw draw spindle (4) into crankshaft.
2. Check reference dimension A ( Page 267).
3. Read off push-on dimension at drive flange (1).
4. Mount installation/removal tool as per overview
drawing ( Page 267).
5. Screw in connecting piece (2) in drive flange (1).
6. Connect HP line for drive flange expansion to
connecting piece.
7. Insert adapter in connection of hydraulic nut (3).
8. Connect HP line (6) to adapter.
10. Back off nut (5) for a distance equaling push-on
dimension.
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11. Fill hand pumps (1) and (2) with engine oil SAE 10.
12. Vent hand pumps (1) and (2) and line system until
14. Operate hand pump (2) to bring hydraulic nut at
minimum pressure p
2
(start of pressure increase)
to attachment with drive flange.
15. Read off max. expansion pressure p
max
at
drive flange.
16. Actuate hand pump (1) to expand the drive flange
until half the maximum expansion pressure p
1
has been reached.
1
18. Increase expansion pressure gradually in
steps of 0.1 x p
max
with hold times of approx.
2 minutes until the drive flange comes clear off the
crankshaft. Do not exceed maximum expansion
pressure p
max
.
pressure.
2
of the drive flange from the taper seat is indicated
by rising pressure p
2
.
21. Gradually relieve pressure in hydraulic nut while
steadily operating pump for expansion fluid.
22. Relieve hand pumps (1) and (2).
23. Screw eyebolt into drive flange and suspend drive
flange on crane with rope lightly tensioned.
24. Remove installation/removal tool.
25. Remove drive flange (1) from crankshaft (2).
26. Remove screws (4) from adapter flange (3).
27. Remove adapter flange (3).
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5.3.22 Vibration damper on PTO, free end Disassembly
Vibration damper Disassembly
Disassembly of this component is not planned.
This component is an exchange component (Reman) and is available via the normal exchange procedure.
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5.3.23 Vibration damper on PTO, free end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning vibration damper
2. Remove cleaner.
3. Blow out components with compressed air.
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5.3.24 Vibration damper on PTO, free end Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Micrometer, 175-200 mm Y20001744 1
Holder 0015890321/00 1
Spare parts
Vibration damper
Drive flange
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Vibration damper - Check
Item Findings Task
Visually inspect vibration damper for
damage and wear.
Damage
Wear
visible
Replace vibration damper.
Using a precision bore gauge,
measure vibration damper bore.
Values ( Page 275)
Values exceeded. Replace vibration damper.
Measure drive flange OD with
micrometer. Values ( Page 275)
Values below specification. Replace drive flange.
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5.3.25 Vibration damper on PTO, free end Tolerances
limit
Basic
size
lower
upper
min.
max.
min.
max.
ID of vibration
damper
198.000
H7
0 +0.046 0 0.059 0.016 1
OD of driver
flange
196.00
j6
0.013 +0.016
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5.3.26 Vibration damper on PTO, free end Installation
Special tools
Removal/installation device F0140771 1
Hook-ended chain sling (quadruple branch) T80090748 1
Material
Engine oil
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
CAUTION
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Installing adapter flange
1. Coat O-rings with grease and insert into groove.
2. Install adapter flange with O-rings as shown in the overview drawing ( Page 267).
3. Use torque wrench to tighten screws to specified tightening torque ( Page 80).
Hydraulic press-fitting drive flange
1. Clean, degrease and dry tapers of crankshaft
and vibration damper.
2. Coat running surfaces of crankshaft bearing and
drive flange with oil.
3. Push drive flange onto crankshaft taper by hand.
4. Measure distance from crankshaft end face to
drive flange end face using depth gauge and
note measured value.
5. Calculate difference (= push-on distance) between
measured dimension and push-on dimension
( Page 267).
6. Push-on dimension B = distance between
crankshaft end face and drive flange end face
after installation.
7. Read off push-on distance at drive flange.
8. If calculated push-on distance is less than
measured value, check dimensional accuracy
of tapers.
9. Screw puller spindle (4) into crankshaft.
10. Check reference dimension (A) ( Page 267).
11. Mount installation/removal device as shown in the
overview drawing ( Page 267).
12. Slide thrust sleeve (1) and hydraulic nut (3)
over puller spindle.
13. Set hydraulic nut (3) to initial position at zero
stroke.
14. Install nut (5) and hand-tighten.
15. Screw high-pressure line with connecting piece (2)
into drive flange.
16. Connect high-pressure line (6) of hydraulic unit
to hydraulic nut (3).
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17. Fill hand pump (1) and (2) with engine oil acc.
to SAE 10 W.
18. Vent hand pump (1) and (2) and pipework until
19. Tighten high-pressure line.
20. Prior to hydraulic press-fitting, moisten tapers fit
with expansion fluid. For this purpose, actuate
hand pump (1) until expansion fluid emerges
at drive flange end.
21. Operate hydraulic hand pump (2) for hydraulic
nut and, by applying minimum pressure on drive
flange, seat against drive flange.
22. Pump in expansion fluid until expansion pressure
p
1
no longer rises. Then increase press-on force
by raising force-on pressure p
2
.
23. Repeat this process until drive flange is correctly
seated.
24. Select push-on pressure so as to achieve
positioning in approx. 5 steps.
25. Read off expansion pressure p
max
at drive flange.
Ensure that, during installation, the required
expansion pressure is less than the maximum
expansion pressure p
max
.
Result: Hydraulic installation is completed when
thrust sleeve is seated against crankshaft.
expansion pressure.
28. Disconnect high-pressure line.
29. Remove installation/removal device after specified
hold time has elapsed.
30. Check push-on dimension (B) between crankshaft
end face and drive flange end face ( Page 267).
31. If push-on dimension is not established,
hydraulically remove drive flange and determine
the cause.
32. Do not subject press fitting to operating load
for at least 8 hours.
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Installing vibration damper
1. Screw adjusting mandrels (1) into threaded hole
of drive flange.
2. Coat O-rings (2) with grease.
3. Fit O-rings (2) on drive flange.
4. Attach vibration damper (1) with lifting gear (3) and
support bracket to crane using a lightly tensioned
hook-ended chain sling.
5. Push vibration damper (1) onto adjusting
mandrels (2).
6. Remove lifting gear (3).
7. Coat thread and screw head mating faces with
engine oil and screw in.
8. Remove adjusting mandrels.
9. Install remaining screws and washers and tighten
to specified tightening torque ( Page 80) using a
torque wrench.
10. Install protective cover.
11. Remove positioning fixture from end housing.
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5.3.27 Piston and conrod Overview
Piston and conrod
1 Piston
2 Conrod
3 Conrod cap
4 Conrod bearing shell, upper
5 Conrod bearing shell, lower
6 Conrod screw
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Piston details
1 Snap ring
2 Piston pin
3 Rectangular-section ring
4 Taper-face compression ring
5 Oil control ring
6 Piston
7 Pressure plate
8 Piston crown screw
9 Conrod
10 Conrod cap
11 Conrod screw
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5.3.28 Piston and conrod Removal
Special tools
Barring tool, 8V-16V F6555766 1
Barring tool, 20V F6783293 1
Barring tool for timing disc F6555791 1
Pointer for barring tool F6555792 1
Timing disc, free end Y4341124 1
Socket, 22 A/F, conrod screws F30378352 1
Lifting device for piston removal, 8V-16V T80091025 1
Lifting device for piston removal, 20V T80091496 1
Sliding block F6559604 1
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Removing piston and conrod with oil pan installed
1. Remove combustion residues from cylinder liner.
2. Remove carbon scraper ring (arrowed)
( Page 134).
3. Install barring tool.
4. Remove left and right-side inspection port cover on
respective cylinder.
5. Position piston of respective cylinder at 20 to 25
mm before after (A-bank) and at 20 to 25 mm
before TDC (B-bank) as measured from the top
edge of the cylinder liner to the piston crown.
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6. Working through the inspection port (arrowed),
slacken conrod screws using a socket insert and
large ratchet.
7. For further removal, except for altered removal
position of crankcase: see "Removing piston and
conrod in assembly dolly" in next section.
8. Before removing the conrod from cylinder liner (3),
attach sliding block (2) to conrod (1).
Removing piston and conrod in assembly dolly
Note: Do not bar crankshaft unless the flywheel
or axial locating device is installed.
1. Turn crankcase in assembly dolly until conrod
bearing cap (1) of the piston to be removed
is horizontal.
2. Using socket (2), extension and ratchet, release
conrod screw (3).
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Note: Bearing cap and conrod are a single unit
and must not be interchanged.
3. Check marking (arrowed) of conrod bearing cap
and conrod. If necessary, mark components.
4. Remove conrod screws (arrowed) and take off
conrod bearing cap (1).
5. Remove bearing shell from conrod bearing cap.
Ensure that toothing on mating faces of conrod
and conrod bearing cap is not damaged.
6. Protect bearing shell and conrod bearing cap
from damage.
7. Check markings of bearing shell to conrod. If
necessary, mark components.
8. Turn crankcase in assembly dolly until the piston
and conrod to be removed are vertical. Ensure
that the oil spray nozzle is not damaged.
9. Remove bearing shell from conrod and protect
from damage.
10. Attach lifting device (1 ) to piston crown (2).
11. Using a crane, withdraw piston and conrod from
cylinder liner fit.
12. Carefully set down piston and conrod on soft
surface and remove from crane.
13. Remove lifting device from piston crown.
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5.3.29 Piston and conrod Disassembly
Special tools
Piston-ring pliers F30378003 1
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Removing conrod from piston
1. Place piston and conrod on workbench.
2. Check markings of conrod, piston and piston pin. If
necessary, mark components anew.
3. Using snap ring pliers (1), remove snap ring (2).
4. Use a piece of round wood to press out piston pin
(2), holding conrod (1) firmly in position.
5. Remove conrod from piston.
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Removing piston rings
1. Stretch piston rings until they can be removed
from the piston.
2. Remove piston rings with piston ring pliers in
sequence from top to bottom.
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5.3.30 Piston Cleaning
Material
Cleaner (Sima Solv K6) 50632 1
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
Avoid open flames, electrical sparks and ignition sources.
Wear goggles/facial protection.
Only work in a well-ventilated room.
Do not smoke.
WARNING
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
Piston cleaning
Note: The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners!
1. Clean all metallic parts with the cleaner.
2. Clean area of piston ring grooves with rotating plastic brush.
3. After cleaning, blow out oil chamber and oil bores with compressed air.
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5.3.31 Piston Check
Material
Dye penetrant (standard check) 40488 1
Spare parts
Piston
Piston pin
Oil-control ring
Taper-face compression ring
Rectangular-section ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
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Piston Check
Item Findings Task
Make sure that oil chamber and oil
bores are particularly clean.
Not clean Clean
Check piston with fluorescent
penetrant.
Signs of cracks Replace piston.
Check piston for wear Contact erosion at piston edge
and valve clearance pockets
Large area of polishing wear
on piston skirt (appears dull)
Concentrated occurrence of
scoring
Pitting
Replace piston.
Measure piston pin boss. Values
( Page 291)
Values exceeded Replace piston.
Check sliding surface of bronze
bush for stress marks and scoring.
Stress marks
Scores
visible
Replace piston.
Check groove width with gauge
blocks. If no gauge block is
available, alternatively a new piston
ring can be inserted in the groove
and the axial play checked with a
feeler gauge. Values ( Page 291)
Values exceeded. Replace piston.
Check piston pin with magnetic
crack-testing method for cracks.
Signs of cracks Replace piston pin.
Check condition of piston. Traces of wear
Scores
Impact points
visible
Replace piston pin.
Measure outer piston pin diameter
with C-frame micrometer. Values
( Page 291)
Values exceeded. Replace piston pin.
Check piston rings. Piston ring with burring,
chipping or sharp edges
If chrome layer has signs
of scoring, cracks or heat
discoloration.
Replace
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Piston rings Check
1. Place piston ring (1) in ring gauge (3) to measure
piston ring end clearance. Ensure that piston ring
fits evenly in ring gauge.
2. Check ring end clearance with feeler gauge (2).
3. If values are exceeded ( Page 291), replace
piston rings. Replace piston rings only in sets.
4. After installation of new piston rings, replace
cylinder liners ( Page 134).
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5.3.32 Piston Tolerances
Piston bearing
Deviation Clearance Interference Wear limit No. Designation Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
Bush inner
dia.
68.000 +0.070 +0.080 1
Piston pin
outer dia.
68.000 0.005 0
0.070 0.085 Clearance max.
0.090
Bush inner
dia.
68.000 +0.012 +0.022 2
Piston pin
outer dia.
68,000 0,005 0
0,012 0,027 Clearance max.
0.025
3 MTU part number and stage stamped on
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Piston rings
Deviation Clearance Interference Wear limit No. Designa-
tion
Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
Groove
width
4,000 +0,170 +0,190 1
Rectan-
gular-sec-
tion ring
4,000 0,035 0
0.300
Groove
width
4,000 0,080 0,100 2
Taper-
face com-
pression
ring
4,000 0,035 0
0.200
Groove
width
5,000 +0,080 +0,100 3
Oil control
ring
5,000 0,035 0
0.200
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tion
Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
Joint clearance Clearance max.
Rectan-
gular-sec-
tion ring
0,400 0,700 0,900
Taper-
face com-
pression
ring
1,000 1,300 1,500
Oil control
ring
0,450 0,800 1,000
4
Measure joint clearance in ring gauge 165.000
H6
.
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Piston clearance in cylinder liner
limit
Basic size
lower
upper
min.
max.
min.
max.
Cylinder liner
dia.
165.000
H7
0 +0,040 1
Piston skirt
dia.
164,805 0,011 +0,011
0,184 0,246
Cylinder liner
dia.
165.000
H7
0 +0,040 2
Piston skirt
dia.
164.720 0.010 +0.010
0,270 0,330
Cylinder liner
dia.
165.000
H7
0 +0.040 3
Piston crown
dia.
164.580 0.020 +0.020
0.400 0.480
Cylinder liner
dia.
165.000
H7
0 +0.040 4
Piston crown
dia.
164.525 0.020 +0.020
0.455 0.495
Scraper ring
dia.
164.000
H8
0 +0.063 5
Piston crown
dia.
163.390 0.025 +0.025
0.585 0.698
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limit
Basic size
lower
upper
min.
max.
min.
max.
Dimensions 1 to 5 measured vertically in relation to pin axis.
Scraper ring
dia.
164.000
H8
0 +0.063 6
Piston crown
dia.
163.267 0.025 +0.025
0.708 0.821
7 Piston skirt round falling oval
Skirt graphite-coated with two positions at 1 and 2 respectively free of graphite for measuring the diameter.
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Piston crown mounting
limit
No. Designation Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
49.000 0.100 +0.100
max.
length
49.800
1 Screw length
removed
50.000 0.100 +0.100
max.
length
50.800
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5.3.33 Conrod Disassembly
Spare parts
Conrod
Conrod Disassembly
1. Disassembly of conrod is not planned.
2. The conrod is an exchange component (Reman) and is available via the normal exchange procedure.
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5.3.34 Conrod Cleaning
Material
Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Conrod Cleaning
1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse with cleaning agent (Hakupur 312).
2. Clean conrod oil bore with hole brush.
3. Use a brass brush to clean meshing on conrod and conrod bearing cap mating faces.
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5.3.35 Conrod Check
Special tools
Testing device Y4341492 1
Test mandrel Y4341913 1
Bore gauge, 18-100 mm Y20091481 1
Bore gauge, 100-160 mm Y20091482 1
Material
Spare parts
Conrod
Conrod screw
WARNING
Compressed air.
Risk of injury!
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Conrod Check
Item Findings Task
Check conrod main bore for blue
discoloration.
Blue discoloration Replace conrod.
Check conrod bushing for scores,
contamination, stress marks and
heat discoloration marks.
To be carried out only in
Replace conrod bush.
Check conrod, conrod bearing cap
and conrod bearing screws for
cracks using magnetic crack-testing
method.
Check threads of conrod and conrod
screw for damage.
Damaged Replace conrod.
Replace conrod screw.
Check conrod screw length. Values
( Page 306)
Value exceeded Replace
Check basic bore for stress marks
and scores.
Stress marks
Scores
visible
Corrective work
Replace
Inspect meshing for damage and
check wear pattern with engineers
blue.
Damaged Replace
Measuring conrod basic bore
1. Assemble conrod ( Page 310).
2. Before measuring, rub down basic bore (2) with
emery cloth.
3. Adjust bore gauge (1) and measure main conrod
bore ( Page 306).
4. If values are exceeded, replace conrod.
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Measuring conrod main bore with bearing shells
1. Coat sliding surfaces of bearing shells with
engine oil.
2. Measure conrod bearing bore. Values
( Page 306).
3. Enter measured values in data sheet.
4. Replace bearing shells if limit values are fallen
short of or exceeded.
5. Remove conrod screws, conrod cap and bearing
shells.
Measuring conrod bush from piston pin end
1. Set bore gauge (1) to zero dimension of conrod
bushing bore and measure conrod bush bore (2).
Values ( Page 306).
2. Values exceeded: Replace conrod bush only in
Checking conrod bush axial fit
1. Use test mandrel (1) and hydraulic press to
check conrod bush axial fit. Required test force F
( Page 306).
2. If test force is not reached, replace conrod.
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1 Dial gauge for axial parallelism
2 Test mandrel, small conrod bore
3 Dial gauge for conrod twist
4 Conrod
5 Test mandrel, large conrod bore
6 V-block
7 Base plate
8 Resilient stop
9 Adjustable dial gauge holder
Checking conrod bore axial parallelism and twist
1. Before inspection, install conrod bearing cap and
tighten conrod bearing screws.
2. Insert test mandrel (2) in large conrod bore so that
wide fit of test mandrel (arrow) faces conrod shaft
and narrow fit faces conrod bearing cap.
3. Clamp test mandrel (2) firmly with locking screw,
ensuring that test mandrel (2) does not tilt.
4. Insert test mandrel (1) in small conrod bore so that
and narrow fit faces oil bores of small conrod bore.
5. Clamp test mandrel (1) with locking screw.
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Checking axial parallelism
1. Insert conrod with test mandrel (3) in V-blocks
(4) of testing device.
2. Place test mandrel (2) on spring-mounted stop (5).
3. Adjust the rigid stop of adjustable stop so that
axle of test mandrel (2) is approx. 2.0 mm below
dial gauge pointer (1).
4. Adjust dial gauges so that their readings indicate
approx. 2 mm preload at highest point on test
mandrel axis, and set to zero.
5. Turn conrod through 180 and carefully place in
testing device.
6. Move test mandrel (2) through dial gauge pointers
at highest point on mandrel axis.
7. Determine and record deviations from zero on dial
gauges.
Checking axial twist
1. Set both dial gauges (1) for axial twist with setting
gauge (2) via dial gauge pointer to zero.
2. Remove setting gauge (2) from testing device (3).
(3) of testing device. Fixed support of adjustable
stop is set so that dial gauge pointer travel is
approx. 2 mm.
4. Press conrod at small conrod bore on fixed
support.
5. Read off and note values on dial gauges (1).
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Calculating axial parallelism
Note: The testing device is set for measuring
axial parallelism at 200 mm intervals.
1. In order to obtain the correct value to 100 mm
clearance ( Page 306), calculate recorded value
on dial gauges as shown in the following example.
Description Value
Left dial gauge A = 0.05 mm
Right dial gauge B = +0.03 mm
Result = 0.08 mm
Result: Axial parallelism: 0.08 mm : 4 = 0.02 mm
2. Compare calculated value to ( Page 306) .
3. If limit value is exceeded, replace conrod.
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Calculating axial twist
1. To determine axial twist of conrod bores, calculate
value measured at 100 mm intervals as shown in
example.
Description Value
Left dial gauge A
1
= 0.06 mm
Right dial gauge A
2
= +0.04 mm
Difference = 0.10 mm
Result: Axial twist A = 0.10 mm : 2 = 0.05 mm
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5.3.36 Conrod Tolerances
Conrod bearings
Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
H6
0 +0.025
0 - 0 117.082
0 - 1 116.882
0 - 2 116.682
Conrod bearing
bore
Conrod bearing
installed
0 - 3 116.482
0 +0.048
0 - 0 117.000 h6
0 - 1 116.800 h6
0 - 2 116.600 h6
2
Crankpin
0 - 3 116.400 h6
0.022 0
0.082 0.152
Crankpin length 97.500 0.100 +0.100 3
0.200 0.600
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Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
0 - 0 126.400
0 - 1 126.400
0 - 2 126.400
4 Expanding
dimension
Conrod bearing
shell, upper and
lower part
0 - 3 126.400
0 +1.000
Conrod screw length
Basic
size
lower
upper
min.
max.
min.
max.
1 Screw length
removed
103.000 0.400 +0.200 104.500
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Conrod bore parallelism
Basic
size
lower
upper
min.
max.
min.
max.
1 Conrod length
8/12/16V
354.000 0.100 +0.100
1 Conrod length
20V
364.000 0.100 +0.100
2 Axial parallelism
Inclination
0.070 over a distance of 100 mm Inclination
max. 0.100
3 Axial parallelism
Twist
0.250 over a distance of 100 mm Offset
max. 0.350
Conrod weight
8/12/16V
9.530 kg -0.060
kg
+0.060
kg
Conrod weight 20V 9.580 kg -0.060
kg
+0.060
kg
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Small conrod bore
Basic
size
lower
upper
min.
max.
min.
max.
0 75.000 H6
1 75.200 H6
Conrod bore
2 75.400 H6
0 +0.019
0 75.000 v6
1 75.200 v6
1
Conrod bushing
outer dia.
2 75.400 v6
+0.120 +0.139
0.101 +0.139
2 Conrod bushing
inner dia.
68.000 +0.070 +0.080
F Axial test force for 8/12/16V conrod: 17,000 N (tested conrod bushings are marked "X")
F Axial test force for 20V conrod: 30,000 N (tested conrod bushings are marked "X")
A Edges rounded
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5.3.37 Conrod Assembly
Special tools
Socket, WAF 22 conrod screws F30378352 1
WARNING
Compressed air.
Risk of injury!
Preparing conrod
1. Blow out mating faces (arrowed) on conrod and
conrod bearing cap with compressed air and clean.
2. Wipe bearing shell mating faces on conrod and
conrod bearing cap.
3. Prior to installing bearing shells (1), compare
repair stage marking on connecting rod and in
crankshaft data sheet.
4. Mark bearing shells according to cylinder number
on front face (A).
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5. Clamp conrod in assembly dolly or in bench
vise with aluminum jaws with mating face in
horizontal position.
6. Place lower conrod bearing (grooved bearing) (2)
in conrod bearing cap so that bearing shell recess
engages in locating pin.
7. Place upper conrod bearing (sputtered bearing) (1)
in conrod so that conrod bearing projects approx.
40 (arrowed) over short conrod arm.
8. Carefully press conrod bearing cap by hand
onto conrod.
9. Pay attention to locating pin and correct location of
bearing shell.
10. Coat threads of conrod bearing screw head
mating face and screw head seating surfaces
with engine oil.
Note: Thread must not be recut.
11. Carefully insert conrod bearing screw into bore in
conrod bearing cap by hand until initial contact
with thread flanks is established, then turn first
three turns without a tool.
12. Install conrod bearing screws until screw heads
make contact and use socket wrench to tighten
firmly by hand. Ensure that conrod and conrod cap
serrations is closed at short and long conrod arms.
13. Use torque wrench (1) to tighten conrod bearing
screws to specified tightening torque ( Page 80).
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5.3.38 Piston Assembly
Special tools
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Installing piston rings
1. Turn coiled spring expander (2) in oil control ring
(1) in order to offset ring spring butting face (arrow)
to oil control ring butt by 180.
3 Oil control ring
2. Prepare piston rings as per installation sequence.
Note that new piston rings must be replaced in
sets.
3. After replacing piston rings, replace cylinder
liners ( Page 134).
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4. Stretch piston rings with pliers so that they can be
fitted over the piston.
5. Insert piston rings in sequence from bottom
upwards (oil control ring first) in the annular
grooves on the piston so that the TOP marking on
the piston rings faces the piston crown.
6. Check that piston rings move freely in their
grooves.
7. Wipe down piston pin, conrod bushing and piston
pin bore with chamois leather and coat with
engine oil.
8. Insert conrod (1) according to markings into
relevant piston (2) in such a way that the shorter
end (A) of the angle-split conrod faces piston
cooling oil bore (B).
9. Insert corresponding piston pin (2) in piston and
conrod (1) until it makes contact with installed
snap ring.
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10. Use snap ring pliers to insert second snap ring.
11. Ensure snap ring is perfectly seated and correctly
positioned (arrow).
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5.3.39 Piston and conrod Installation
Special tools
Assembly jig F6553635 1
Lifting device for pistons, 8V-16V T80091025 1
Lifting device, 20V T80091496 1
Assembly sleeves F6557121 1
Socket, 22 A/F F30378352 1
Barring tool F6555791 1
Material
Engine oil
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
Compressed air.
Risk of injury!
Assemble piston ( Page 312).
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Preparing crankcase in assembly dolly
1. Rotate crankcase in assembly dolly until cylinder
liner (arrow) is vertical.
2. Turn crankpin of crankshaft of piston to be installed
and connecting rod to assembly position.
3. Wipe crankpin and running surface of cylinder
liner and spray with engine oil.
Preparing piston for installation
1. Spray the piston and piston rings with engine oil.
2. Ensure that piston rings (arrow) are evenly fitted at
120 around piston circumference.
3. Center piston rings and oil control ring in grooves.
Preparing conrod bearing for installation
1. Blow out interfaces (arrows) on connecting rod and
conrod bearing cap with compressed air and check
that they are clean.
2. Wipe bearing shell mating faces on connecting
rod and conrod cap.
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3. Fit bearing half shell of conrod bearing cap
(grooved bearing) in assembly device (1) so that
the recess (3) of the conrod bearing engages in
the locating pin (2) of the device.
4. Coat running surface of bearing shell with engine
oil.
5. Press assembly device (arrow) with bearing shell
half by hand onto crankshaft crankpin.
6. Coat running surface of bearing half shell for
conrod (sputtered bearing) with engine oil.
7. Position bearing shell half (1) according to recess
for locating pin on crankpin (2) so that the two
recesses are aligned.
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Note: In order to guide the conrod and avoid damage
to the oil spray nozzle, piston installation must
be carried out by two people. Install piston
without carbon scraper ring.
Installing piston and conrod in cylinder liner
1. Attach lifting appliance (1) for piston (2).
2. Place piston assembly sleeve (3) with chamfered
side up on cylinder liner (4).
3. Oil assembly sleeve and cylinder liner inside.
4. Install piston into cylinder liner so that short arm
of conrod points outwards to air intake side.
Turn piston slightly so that oil spray nozzle is
not damaged.
5. Place conrod on assembly device (2) for conrod
bearing.
6. Position assembly device with guide pin (1).
7. Remove assembly device and press conrod cap
by hand onto conrod. Pay attention to fit of locating
pin in recess in conrod cap.
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Installing conrod bearing cover
1. Coat thread and underside of screw head with
engine oil.
2. Insert conrod bearing screws (arrow) into screw
bore on conrod cap by hand, then turn first three
rotations without a tool.
3. Fit conrod bearing screws (arrow) up to screw head
and tighten firmly by hand using socket wrench,
ensuring that conrod serrations are closed.
4. Use torque wrench to pretighten conrod screws to
5. Check that conrod has axial play.
6. Use torque wrench to tighten conrod screws to
7. Check axial clearance of conrod.
8. Remove lifting device and assembly sleeve for
piston with conrod.
9. Bar crankshaft and ensure that there is ease of
movement between oil spray nozzle, piston
and conrod.
Installing piston with connecting rod with oil pan
installed
2. Before installing piston and conrod, fit sliding block
(2) on conrod to be installed.
3. Further installation procedure with oil pan removed
(previous sections).
4. After installation, remove barring tool.
5. Install inspection port cover on left and right side of
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Checking conrod axial clearance in assembly dolly
1. Use feeler gauge to check distance between
crankshaft web and conrod or between conrod and
conrod, pressed towards each other.
2. If axial clearance is below the minimum of min. =
0.20 mm or above the maximum of max. = 0.60
mm, measure pressed at three levels, readjust
clearance.
3. Release conrod screws and compensate axial
clearance.
4. First tighten conrod cap screw on short conrod arm
and then on long conrod arm with torque wrench to
specified pretightening torque ( Page 80).
5. Again check axial clearance.
6. Use torque wrench to tighten conrod bearing
screws to specified tightening torque ( Page 80).
1. Spray edge of cylinder liner and carbon scraper
ring with engine oil.
2. Insert carbon scraper ring.
Setting TDC indicator
1. Install pointer (1) on equipment carrier.
2. Install index plate (2) on crankshaft, free end, set
to TDC marking of A1 and tighten.
3. Set piston A1 to firing TDC.
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4. Install dial gauge (2) under preload in measuring
device (4) and clamp with screw (1).
5. Install measuring device into cylinder head and
secure with knurled-head screw (3).
6. Set dial gauge to zero.
7. Move piston several times up and down through
TDC until needle of dial gauge registers its highest
reading.
8. Set dial gauge to zero and readjust timing disc
accordingly.
9. Bar crankshaft in normal engine direction of
rotation to 5 before TDC, read dial gauge and
make a note of measured value.
10. Bar crankshaft past TDC to approx. 10 (to
take up bearing play).
11. Bar crankshaft against normal direction of engine
rotation to 5 after TDC, read dial gauge and make
a note of measured value.
12. Calculate mean value.
13. Bar crankshaft to approx. 10 after TDC, then bar
in direction opposite to normal direction of rotation
until dial gauge shows calculated mean value.
14. Set pointer of timing disc to 5 after TDC and
tighten.
15. Rotate crankshaft to approx. 10 before TDC.
16. Repeat working steps 9 to 11 until measured
values at same degree figure are identical.
Result: Absolute TDC reached.
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5.4 Cylinder Head
5.4.1 Cylinder head and attachments Overview
Cylinder head and attachments Overview
1 Cylinder head
2 Inlet valve
3 Exhaust valve
4 Valve spring, inner
5 Valve spring, outer
6 Spring retainer
7 Valve collet
8 Valve rotator
10 Plug screw
11 Sealing ring
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2 Valve-seat insert, inlet *
3 Valve-seat insert, exhaust *
4 O-ring
5 Sleeve
6 Valve guide
7 Plug
8 Plug
9 Plug
11 Cylinder head
* Only on cylinder heads of
corresponding design
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1 Sealing ring
2 Gasket
3 Cylinder head screw
4 Thrust washer
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5.4.2 Valve-seat turning machine for cylinder head
Working principle of valve-seat turning machine
The valve-seat turning machine is an inside turning device. While the cutter (3) rotates around the valve-seat
(5), a feed gear mechanism ensures a continuous outward feed motion (1). The feed motion under the proper
valve-seat angle (4) is defined by an inclined slideway in the exchangeable adapter head.
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Installing the solid pilot
Precondition:
Valve guide is installed and machined to finished dimension.
Valve guide was cleaned.
Cylinder head is securely clamped and valve guide accessible from both sides.
Mounting the supporting spider
To achieve maximum accuracy, the pilot must be supported by the supporting spider (7) below the valve seat. Slide
the supporting spider (7) over the pilot shaft to such position that the spring-loaded spider elements (1) rest just
below the valve seat level when the pilot is installed in the valve guide (4) and tighten the clamping screw (6).
Inserting the pilot into the valve guide
Remove clamping nut (3) from pilot and insert the threaded end of the pilot into the valve guide (4), until
the tapered portion (5) bears against the conical seating of the valve guide (4). The spring-loaded elements
(1) of the spider (7) will bear against the exhaust/inlet canal below the valve seat.
Locking the pilot
Screw clamping nut (3) onto the pilot and tighten with moderate force. Tighten the screws (6) on
top of the spider to lock the spring-loaded elements (1) of the spider (7). Apply standard machine
oil to the top and around the periphery of the pilot shaft.
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Setting up valve turning machine
Mounting the cutter
Fit the appropriate tool holder of the cutter (8) with an indexable insert and attach to the tool slide (7).
Placing the valve-turning machine on the pilot
Take care that the cutter (8) does not bump against the cylinder head.
Slide the valve-seat cutting machine over the pilot (10) until either the depth stop (3) rests upon
the pilot (10) or the cutter (8) contacts the cylinder head.
Aligning the cutting edge with the valve-seat center
Turn rapid tool adjuster (11) to position cutting edge of cutter over the valve-seat center (9). Hold
the machine with one hand. Loosen screw (4) of depth stop (3) and allow machine to slide down
until the cutting edge contacts the valve seat (9) lightly. Push depth stop (3) slightly downward
against the pilot (10) and then tighten depth stop locking screw (4).
Connecting the machine to power supply
Insert the round plug of the outlet cable (6) of the power supply unit (5) into the corresponding socket
(1) on the driving assembly (2) and allow the securing latch to engage.
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Valve seat turning
Positioning the cutter at the inner valve-seat edge
Slightly lift machine with one hand and then turn rapid tool adapter (11) with the other hand until the
cutting edge is just clear of the inner edge of the valve seat (10).
Setting cutting depth
To set the depth of cut, turn depth feed (3) counterclockwise. One notch of the depth-feed scale (4) corresponds
to a depth feed of 0.025 mm. As the valve seat (10) usually shows unequal wear, the depth of the first turning
cycle must be selected (max. 0.2 mm) to ensure that the entire valve-seat surface is undercut.
If the cutting edge is just scraping along the surface instead of undercutting the hard surface zone,
there is a risk of premature wear and chipping of the cutting edge.
Lubricating the valve seat
Apply a few drops of metalworking lubricant on hard valve-seat surfaces before turning.
Valve seat turning
Make sure that the pivoted lever (8) is engaged in the groove of the feed actuator (12). Select proper speed by
shifting the switch (6) at the power supply unit (5). Speed can be increased by changing over from 30 VDC to 42 VDC.
Hold driving unit (2) with both hands at the motors (1) and press pushbutton switch (7) to start the cutting pass.
Release the pushbutton switch (7) as soon as the cutter has been traversed beyond the top edge of the valve seat (10).
Repeating the cutting pass
Repeat steps with a cutting depth between 0.05 mm and 0.1 mm until the valve seat surface (10) is plane all around.
To ensure a smooth valve-seat surface (10) finish, proceed with a final pass at high speed with 0.025 mmcutting depth.
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Replacing the adapter head
Removing the adapter head
Unscrew the two screws (1) from the adapter head (2).
Turn adapter head (2) in the direction of the arrow until the back of the toothed rack (4) is no longer engaged with
the pinion (4) in the gear housing (6). Now the adapter head can be withdrawn off the gear housing (6).
Mounting the adapter head
Place adapter head (2) onto gear housing (6) so that the pinion (5) projecting from the gear housing (6)
is seated in the corresponding bore of the adapter head (2).
The adapter head (2) must be seated flush with the gear housing (6).
Screw the two screws (1) loosely into the gear housing so that the adapter head (2) can still be moved
to adjust proper clearance between toothed rack (4) and pinion.
Adjust the adapter head so that the gap between the toothed side of the rack (4) and the opposite side of
the recess (3) is approximately 0.3 mm to 0.5 mm. Tighten both screws (1).
Turn the rapid tool adjuster to move the tool slide back and forth. If tool slide does not
move freely, readjust the adapter head.
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5.4.3 Cylinder head Removal
Preconditions
Special tools
Removal tool F6553658 1
Plug B80144872 1
Installation/removal tool for plugs F30378956 1
WARNING
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
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Cylinder head Removal
1. Release hex bolts (1) on the cylinder head with
power amplifier (2) evenly and unscrew.
2. Screw plug (2) on to installation/removal tool and
lock it by turning the handle (1).
3. Screw plugs with installation/removal tool (1) into
oil supply line (arrow) in crankcase and spread.
4. Ensure that the plug is firmly anchored.
5. Release installation/removal tool (1) and remove.
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6. Suspend cylinder head (2) with support bracket (1)
on crane with rope lightly tensioned.
7. Lift off cylinder head (2) and lower onto a firm
surface.
8. Remove cylinder head gasket from mating face
of crankcase.
9. Remove plug from oil supply bore and close
with protective plug.
10. Use a screwdriver to remove sealing ring from
lower side of cylinder head.
11. Seal openings with suitable plugs.
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5.4.4 Cylinder head Disassembly
Special tools
Valve spring compressor F6783833 1
Socket F30377634 1
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
Only use specified tool and equipment.
Removing valves
1. Place cylinder head on base plate (3).
2. Mount valve-spring compressor (2).
3. Screw in spindle (1) and compress valve springs
with valve-spring compressor (2) until the valve
collets (4) can be removed.
4. Remove valve collets (4) with a magnet.
5. Release valve springs and remove valve-spring
compressor (2).
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6. Remove valve spring retainer, valve springs
and valve rotators.
7. Lay cylinder head on its side.
8. Mark exhaust and inlet valves so that they can be
reinstalled in their original positions.
9. Place valves in storage rack (1).
Removing sleeve
1. Secure cylinder head.
2. Using socket, remove sleeve from cylinder head.
3. Remove O-ring from sleeve.
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5.4.5 Cylinder head Cleaning
Material
Cleaning agent (Snow-White 11-0) 40460
Cleaning agent (Hakupur 312) 30390
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
CAUTION
Cleaning the cylinder head
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5.4.6 Cylinder head Check
Special tools
Alignment plug gauge, 11.00 mm H7 Y20090113 1
Check gauge for inlet valve seat Y4340442 1
Check gauge for exhaust valve seat Y4340443 1
Removal tool Y4343688 1
Material
Corrosion inhibitor
Spare parts
Cylinder head
Sealing ring
Gasket
Cylinder head screws
Thrust washer
Valve guides
Valves
Sleeve
Valve springs
Sliding pin
Valve rotator
Spring retainer
Valve collet
WARNING
Compressed air.
Risk of injury!
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WARNING
Heavy object.
Risk of crushing!
WARNING
Test liquid is hot and pressurized.
Cylinder head check
Item Findings Task
Measure cylinder head height.
Values ( Page 339)
Minimum height not reached Replace cylinder head.
Check cylinder head mating face
(combustion chamber side) for
evenness and damage.
Damaged Recondition
Replace cylinder head.
Check mating face of sleeve in
cylinder head for scores and wear.
Scores
signs of wear
visible.
Recondition
Measure valve guides with alignment
plug gauge. Values ( Page 339)
Not dimensionally accurate Replace valve guides.
Check valve springs for damage.
Check spring power and length of
valve springs. Values ( Page 339)
Damaged
Values below specification
Replace valve springs
Check thread for ease of movement. Sluggish Recondition
Check valve seats on cylinder head
for pitting and wear.
Pitting or wear Recondition: ( Page 325)
Check cylinder head screw threads,
screw head mating faces and thrust
washer for damage.
Damaged Replace
Values exceeded ( Page 339). Replace
Check valves for damage.
Check valves for concentricity and
dimensional accuracy. Values
( Page 339)
Chrome layer damaged
Valve keyways damaged or
burnt
Out-of-round
Replace
Check spring retainer and valve
collet for scores and wear.
Scores
signs of wear
visible.
Replace
Replace valve guides and valve rotators during extended component repair.
Only for cylinder heads with valve bridge guides.
Check sliding pin and valve bridge
bore for wear and damage. Values
( Page 339)
Signs of wear
Damage visible
Not dimensionally accurate
Replace sliding pin.
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Checking cylinder head for leaks
Note: Install sleeve prior to leak test ( Page 359).
1. Prepare water for water bath with corrosion inhibitor.
2. Install pressure testing device.
3. Place cylinder head in a water bath heated to 80 C until cylinder head has warmed up.
4. Pressure-test cylinder head with 0.5 bar compressed air.
5. Pressure must be maintained with cylinder head in water bath for at least 30 minutes. No air bubbles must
emerge.
6. Remove hydraulic pressure testing device.
7. Replace leaking sealing cover ( Page 357).
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5.4.7 Cylinder head Tolerances
Cylinder head tolerances for heads with valve seat inserts and
exhaust emission certification
Inlet and exhaust valve guides
Basic
size
lower
upper
min.
max.
min.
max.
0 19.000
H7
1 19.100
H7
Cylinder head
bore
2 19.300
H7
0 +0.021
0 19.000
r6
1 19.100
r6
1
Valve guide
external
diameter
2 19.300
r6
+0.028 +0.041
+0.007 +0.041
Valve guide bore
installed
11.000
H7
0 +0.018 2
Valve stem
diameter
10.935 0.010 +0.010
0.055 0.093
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Basic
size
lower
upper
min.
max.
min.
max.
Finished valve
guide bore
installed
11.000
H9
0 +0.043 2
Valve stem
diameter
10.935 0.010 +0.010
0.055 0.118
Valve clearance
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve protrusion
Exhaust
with valve seat
ring
+0.100 up to max.
1.000
2 Valve clearance
or protrusion
Inlet
0.000 up to max.
1.100
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Inlet and exhaust valve seat ring
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve seat ring
bore, exhaust
57.000
H6
0 +0.019
2 Valve-seat insert
- depth
11.200 0.050 +0.050
3 Valve-seat insert
bore, inlet
58.000
H6
0 +0.019
Reconditioning note:
If a valve-seat insert is replaced before reaching the reconditioning depth of 1.100 mm, it must be machined
to the depth of the contour to avoid that the valve-seat insert protrudes into the combustion chamber.
Max. corrective machining or equalizing of valve-seat inserts by 0.300 mm in depth, without machining the
contour and the radius.
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Inlet and exhaust valve-seat insert
Basic
size
lower
upper
min.
max.
min.
max.
1 Plug gauge
diameter
73.200 0 0
2 Plug gauge
diameter
87.130 0 0
3 Valve seat
surface
Reference
dimension
Plug gauge
4.800 0.200 +0.200 up to min.
3.700
4 Cylinder head
depth
Combustion
chamber sealing
ring surface
13.800 0 +0.100
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Inlet valve elliptical chamfer
Basic
size
lower
upper
min.
max.
min.
max.
1 Distance to valve
seat center
2.700 0.150 +0.150
2 Chamfer 0.300
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Exhaust valve
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve head
external
diameter
56.000 0.200 +0.200
Reference
dimension
with ring gauge
for
valve seat
diameter
54.000 2
Valve seat height 4.680 0.200 +0.100 up to min.
3.480
3 Reference
dimension
without ring
gauge for
valve seat height
3.700 0.200 +0.100 up to min.
3.000
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Inlet valve
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve head
external
diameter
57.000 0.200 +0.200
Reference
dimension
with ring gauge
for
valve seat
diameter
54.000 2
3.350
3 Reference
dimension
without ring
gauge for
valve seat height
3.700 0.200 +0.100 up to min.
3.000
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Valve springs, outer
Basic
size
lower
upper
min.
max.
min.
max.
1 Spring length
released
83.900
Spring length
compressed
66.000 2
Spring length
when mod. valve
rotator is used
65.100
2.1 Spring force
at compressed
spring length
530.000 N
Spring length
compressed
51.750 3
Spring length
when mod. valve
rotator is used
50.850
3.1 Spring force at
spring length
pos. 3
952.000 N 39 N +39 N Spring
force
min. 897.000 N
4 Spring length
Block dimension
47.700 Block
dimension
max. 47.700
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Basic
size
lower
upper
min.
max.
min.
max.
5 Winding dia. 34.400
6 Wire dia. 5.300
e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.500
e2 Spring seat, permissible parallelism deviation max. 0.600
Valve springs, inner
Basic
size
lower
upper
min.
max.
min.
max.
1 Spring length
released
78.400
Spring length
compressed
61.000 2
Spring length
when mod. valve
rotator is used
60.100
2.1 Spring force
at compressed
spring length
256.000 N
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Basic
size
lower
upper
min.
max.
min.
max.
Spring length
compressed
46.750 3
Spring length
when mod. valve
rotator is used
45.850
3.1 Spring force at
spring length
pos. 3
466.000 N 19 N +19 N Spring
force
min. 420.000 N
4 Spring length
Block dimension
42.500 Block
dimension
max. 42.500
6 Wire dia. 3.600
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Cylinder head mating surface protective sleeve
Basic
size
lower
upper
min.
max.
min.
max.
1 Cylinder head
height
184.000 0.100 +0.100 183.600
2 Protective sleeve
mating surface
124.000 0 +0.200
Protective sleeve
bore
44.200 0 +0.100 3
Protective sleeve
external
diameter
44.100 0.100 0
0.100 0.300
4 Cylinder head
and protective
sleeve thread
M 24 x 1.5
Rework only until a satisfactory mating surface has been achieved.
When reconditioning cylinder head height, reestablish the fire side contour of 13.800 +0.100.
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Basic
size
lower
upper
min.
max.
min.
max.
1 Cylinder head
screw with
engine lifting eye
333.000 0.300 +0.300
2 Cylinder head
screw
283.000 0.300 +0.300
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5.4.8 Cylinder head Repair
Special tools
Tool kit without elliptical chamfer reconditioning F6783749 1
Tool kit (accessory equipment) for elliptical chamfer reconditioning F6783751 1
Tool kit for valve-seat insert removal F6784421 1
Indexable insert F30450433 1
Mounting plate for valve guide installation F6554300 1
Valve guide extractor F30450348 1
Valve guide mandrel F6781747 1
Reamer, 19.00 mm for stage 0 cylinder head bore F30091631 1
Reamer, 19.10 mm for stage I cylinder head bore F30047578 1
Reamer, 19.30 mm for stage II cylinder head bore F30028269 1
Valve seat contour restoring tool for exhaust valve with valve-seat insert F30450631 1
Valve seat contour restoring tool for inlet valve with elliptical chamfer and
with/without valve-seat insert
F30450632 1
Turning handle for valve seat contour restoring tool 8205890451/00 1
Exhaust valve gauge Y4340443 1
Inlet valve gauge Y4340442 1
Valve seat test device Y4341935 1
Countersink reamer tool F30451554 1
Inserting mandrel for valve-seat insert, inlet F30450751 1
Inserting mandrel for valve-seat insert, exhaust F30450750 1
Material
Liquid nitrogen
Corrosion inhibitor
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Spare parts
Valve guide, inlet
Valve guide, exhaust
DANGER
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
CAUTION
CAUTION
Removing the valve-seat insert
1. Clean valve guide using a hole brush.
2. Insert pilot into valve guide of cylinder head
(3) and secure.
3. Install head (2) and lathe tool on valve seat
lathe (1).
4. Position valve seat lathe (1) on pilot and install
steady rest.
5. Setup valve seat lathe (1) ( Page 325).
6. Machine valve-seat insert so that the seat insert
extractor can be installed.
7. Remove steady rest, valve seat lathe (1) and pilot.
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8. Install seat insert extractor (1) on the valve-seat
insert to be removed (2).
9. Using seat insert extractor (1), remove valve-seat
insert (2).
10. Check bore of valve-seat insert (1) in cylinder
head. Values ( Page 339).
Result: Replace cylinder head if the value
is exceeded.
Removing the valve guide
1. Place cylinder head on hydraulic press. Ensure
correct positioning of the cylinder head side.
2. Using the extractor and working from the
combustion side, press valve guide out of cylinder
head.
3. Check valve guide bore in cylinder head. Values
( Page 339).
Result: If the value is exceeded, recondition
bore to next stage.
4. Secure cylinder head on boring mill.
5. Ream valve guide bore in cylinder head.
Installing the valve guide
1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (4) in water bath heated to
80C until cylinder head (4) has warmed up.
3. Chill valve guide (2) in liquid nitrogen for approx.
20 to 30 mins.
4. Position heated cylinder head (4) on assembly
jig (3).
5. Using mandrel (1), position chilled valve guide
(2) in bore of cylinder head (4) until the stop of
assembly jig (3) is reached.
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Installing the valve-seat insert
2. Place cylinder head in water bath heated to 80 C until cylinder head has warmed up.
3. Chill valve-seat insert in liquid nitrogen for approx. 20 to 30 mins.
4. Position heated cylinder head on suitable surface.
5. Using the inserting mandrel, install chilled valve-seat insert into the cylinder head bore until the stop is reached.
Machining the valve seat surface
2. Insert pilot (3) and support (2) into valve guide of
cylinder head (1) and secure.
3. Install suitable head (2) and lathe tool to valve
seat lathe (1).
steady rest.
Note: Note recondition dimension, required when
machining elliptical chamfer.
6. Only recondition valve seat surface until a
satisfactory surface has been established. Values
( Page 339).
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8. Recondition valve seat surface (2) with associated
valve seat contour restoring tool (1).
9. Clean cylinder head after machining.
Checking valve seat concentricity
1. Insert pilot into valve guide.
2. Mount clamp ring (2) over inserted pilot and
secure.
3. Mount the tester (1) on clamp ring.
4. Set preloaded feeler of tester on valve seat
center (arrowed).
5. Check concentricity of valve seat in relation to
valve guide, values ( Page 339).
Result: In event of deviation from test values,
recondition valve seat again.
6. Remove tester (1), clamp ring (2) and pilot.
Measuring valve seat depth
1. Adjust distance from plug gauge to ring gauge.
2. Set scale on dial gauge to zero.
3. Measure valve seat depth. Values ( Page 339).
is exceeded.
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Regrinding valve seats
1. Mount valve (1) as directly as possible behind
valve head in valve grinder (2).
2. Set valve seat grinding angle on valve seat grinder.
3. Using low feed, grind valve seat only until a
satisfactory surface is achieved.
4. Measure height of outer valve seat edge as well as
valve seat width. Value ( Page 339).
Result: If the value is not reached, replace valve.
Reconditioning elliptical chamfer (if required)
1. Insert pilot (3) for elliptical chamfer (2) into valve
guide.
2. Mount tester (1) over inserted pilot (3) and secure.
3. Set preloaded tester pointer (1) to elliptical
chamfer (2).
4. Align pilot (3) and elliptical chamfer (2) using
tester (1).
5. Secure pilot (3).
6. Remove tester (1).
7. Install suitable head and lathe tool to valve seat
lathe.
8. Position valve seat lathe on pilot and install
steady rest.
9. Set up valve seat lathe ( Page 325).
Note: Use recondition dimension as for
machining valve seat surface.
10. Only recondition elliptical chamfer (2) until a
satisfactory surface has been achieved.
11. Check elliptical chamfer (2). Value ( Page 339).
is exceeded.
Reconditioning the protective sleeve mating face.
1. Install countersink reamer tool in bore for protective sleeve.
2. Recondition seating surface for protective sleeve with countersink reamer tool. Value ( Page 339).
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5.4.9 Cylinder head Plug repair
Special tools
Mandrel, 20 mm F30378617 1
Guide sleeve for mandrel F30377862 1
Mandrel, 24 mm F30271842 1
Mandrel, 30 mm F30377635 1
Material
Cleaner (Loctite 7063) 50594 1
Spare parts
Plug
Plug
Plug
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
CAUTION
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Replacing plug
Note: Replace plug only if required.
2. Use pliers to withdraw end cover, taking care that
end cover does not fall into the bore.
3. Clean coolant chambers with cleaner
(Snow-White 11-0), then rinse with cleaner
(Hakupur 312).
4. Blow out coolant chambers with compressed air.
5. Clean mating surface of new plug and cylinder
head bore ensuring they are free of grease and dry.
6. Coat mating surface with screw locking compound.
7. Using a mandrel, knock plug into the cylinder
head bore until flush.
8. Check cylinder head for leaks ( Page 336).
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5.4.10 Cylinder head Assembly
Special tools
Retainer 0015890321/00 1
Torque wrench 20-100 Nm F30026582 1
Socket F30377634 1
Material
Engine oil
Spare parts
O-ring
Sealing ring
WARNING
Risk of injury!
WARNING
Heavy object.
CAUTION
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Installing sleeve
1. Clean sealing surface (arrow).
2. Coat O-ring (2) with grease and insert in groove
of sleeve (1).
3. Clamp cylinder head firmly.
4. Clean sealing surface of cylinder head.
5. Use torque wrench to tighten prepared sleeve
to specified tightening torque .
Sleeve Tightening torque 60 Nm +6 Nm
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Installing valves
2. Wipe valves with chamois leather and coat valve
stems with engine oil.
3. Insert valves in valve guides. Observe correct
valve arrangement. Markings are on the end
of the valve stems.
IN Inlet
EX Exhaust
4. The markings and installation positions of the
valves are located on the upper side of the
cylinder head.
IN 2 x inlet (1)
EX 2 x exhaust (2)
5. The marking is visible on the lower side of the
valve in the form of a countersink.
Inlet (1) = 20 mm
Exhaust (2) = max. 8 mm
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6. Mount supporting plate for valve spring
compressor on cylinder head.
7. Set cylinder head upright.
8. Slide valve rotator on to valve guide.
9. Fit outer and inner valve springs.
10. Fit valve spring retainers.
11. Mount valve spring compressor (2).
with valve-spring compressor (2).
13. Insert valve collets (4) in spring retainer and center.
14. Make sure that lip of valve collet fits firmly in
groove at end of stem.
15. Release valve springs.
16. After installation of all valve collets, remove valve
spring compressor (2) and mounting plate (3).
17. Place cylinder head in installation position or on
its side.
18. Make sure valves move freely.
19. Using a plastic mallet, lightly tap the valve stem to
ensure that the valve collets contact the valve
stem.
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Measuring valve clearance to cylinder head
1. Install dial gauge (2) on dial-gauge holder (1).
2. Set dial gauge (2) with preload on to plane face
of cylinder head (4).
3. Set dial gauge to 0.
4. Position dial-gauge stylus on valve head of
valves (3) and measure valve clearance to plane
surface.
5. If the reading is not within the tolerance
( Page 339), check valve seat at cylinder head
and valve head.
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5.4.11 Cylinder head Installation
Special tools
Carrying bracket T80090944 1
Installation/removal tool for seal plug F30378956 1
Seal plug B80144872 1
Tightening tool (power amplifier) F6553658 1
Alignment tool for 8V and 12V cylinder heads F6558582 1
Measuring tool for angle of rotation Y20044010 1
Material
Engine oil
Spare parts
Sealing ring
Gasket
WARNING
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
CAUTION
CAUTION
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Cylinder head Installation
1. Insert adjusting mandrels (2) in crankcase upper
deck.
2. Fit gasket (1).
3. Ovalize sealing ring by tapping it lightly.
4. Insert sealing ring with groove on combustion
chamber side of cylinder head.
5. When installing sealing ring, ensure position
is correct:
A = Cylinder head side
B = Piston side
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6. Remove seal plug.
7. Attach cylinder head (2) with carrying bracket (1)
and rope to crane, ensuring that the rope is
8. Place cylinder head (2) onto crankcase.
9. Coat thread, shaft and mating surfaces on heads
of cylinder head screws (1) with engine oil.
10. Observe assignment of cylinder head screws (1)
(engine lifting eye). Install cylinder head screws (1)
with thrust washers manually in crankcase.
11. Fit alignment tool (2) on inlet channels of cylinder
heads and tighten.
12. Align cylinder heads.
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A Exhaust side
B Inlet side
13. Use power amplifier and torque wrench to tighten
cylinder head screws to specified tightening torque
in accordance with the tightening sequence.
Cylinder head screw M22 x 2 Preload torque Engine oil 25 Nm
Cylinder head screw M22 x 2 Residual torque 180 Nm +10 Nm
Cylinder head screw M22 x 2 Residual angle of rotation 180 +10
Cylinder head screw M22 x 2 Control torque 400 Nm
14. Remove alignment tool.
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5.5 Valve Gear
5.5.1 Valve gear Overview
Valve gear Overview
1 Camshaft gear
2 Swing follower, inlet
3 Swing follower, exhaust
4 Swing follower shaft
5 Camshaft
6 Pushrod, inlet
7 Pushrod, exhaust
8 Axle
9 Rocker arm, inlet
10 Hex nut
11 Adjusting screw
12 Rocker arm, exhaust
13 Rocker shaft support
14 Valve bridge, exhaust
15 Hex nut
16 Adjusting screw
17 Valve bridge, inlet
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5.5.2 Camshaft overview
Overview of camshaft
1 Hex screw
2 Spring washer
3 Graduated disc
4 Camshaft gear
5 Hex screw
6 Thrust bearing flange
7 Dowel pin
8 Camshaft
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5.5.3 Camshaft Removal
Preconditions
Special tools
Camshaft locating device F6553642 1
Camshaft installation/removal tool F30450435 1
Guide sleeve for camshaft 8V-16V F6782970 1
Guide sleeve for camshaft 20V F6781673 1
Guide sleeve for assembly on driving end F6781676 1
Guide sleeve for assembly on free end F6780579 1
Centering sleeve for assembly on free end F6780582 1
WARNING
Heavy object.
Risk of crushing!
Camshaft drive Removal
1. Remove camshaft gear as shown in overview drawing ( Page 369).
2. To protect the crankcase from falling objects, cover equipment carrier from below.
Removing camshaft thrust bearing
2. Remove thrust bearing flange (2).
3. Check thrust bearing flange ( Page 395).
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Camshaft Removal
1. Install inner guide sleeve (2) on face of camshaft,
free end.
2. Fasten guide flange (1) on crankcase.
3. Fasten outer guide sleeve (3) with screws (1) on
crankcase (2), driving end.
4. Screw inner guide sleeve (4), driving end, on to
camshaft.
5. Center guide sleeve to camshaft bearings.
6. Mount installation/removal tool on camshaft (2).
7. Attach camshaft with rope in middle (1) to crane.
8. Tension rope slightly and carefully withdraw
camshaft (2) horizontally from crankcase.
9. Remove guide sleeve.
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5.5.4 Camshaft Cleaning
Material
WARNING
Camshaft Cleaning
1. Clean all parts with cleaning agent.
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5.5.5 Camshaft running surfaces and swing followers Visual inspection
Special tools
Spare parts
Camshaft
Roller tappet
Visually inspecting camshaft running surfaces
and swing followers
1. Remove valve drive (swing followers remain
installed) DM_110_WM_055050_520A.
2. Insert endoscope into crank drive through every
pushrod bore.
3. Visually check roller surface of cams, roller running
surfaces on the camshaft as well as swing
followers for damage and wear.
4. Replace swing follower if signs of corrosion are
visible, see illustrations (Workshop Manual).
5. Replace camshaft if signs of corrosion are visible,
see illustrations ( Page 387).
Install valve drive DM_110_WM_055050_720A.
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5.5.6 Camshaft Check
Special tools
Hardness tester DynaMIC Y20506341 1
Measuring stand 0015890321/00 1
Material
Spare parts
Camshaft
Camshaft gear
Timing wheel
Hex screw
Spring washer
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Camshaft Check
Item Findings Measure
Using magnetic crack-test
procedure, check camshaft for
cracks.
Crack indication Replace camshaft.
Check axial bearing flange with red
dye penetrant for cracks.
Check mating face of camshaft gear. Stress marks visible Recondition: Smooth with
Replace
Check axial sliding surface, journal
faces and roller tracks of cams
for scores, stress marks and
indentations.
Scores
Stress marks
Indentations
visible
Replace camshaft.
Check tooth flank of camshaft gear
with magnifying glass.
Damaged Replace camshaft gear.
Check screws for damage. Damaged Replace
Checking hardness of cam and journal
1. Use hardness tester to check cam hardness
(inlet/exhaust rocker arms) and journals. Required
hardness: 60 HRC 2 HRC
3. Replace camshaft if values are fallen short of.
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Checking concentricity and cam lift
1. Set camshaft at outer journals on to V-blocks
(2) or roller stands.
2. Place supporting mount (3) on center journal.
3. Measure radial run-out of cam base circle and
bearings with dial gauge (1). Values ( Page 377).
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5.5.7 Camshaft Tolerances
Concentricity of bearings
Max. permissible deviation of
concentricity
New Wear limit
During the concentricity check, provide supports for and align the following bearings.
8V: bearing 3 beginning at driving end
from bearing 1 to bearing 2
0.050
a from bearing to bearing
0.025
b all cams
0.010
0.010
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Axial clearance
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
Camshaft gear
bore
32.000
H7
0 +0.025 1
Camshaft outer
dia.
32.000
H7
0.025 0
0 0.050
2 Axial clearance 0.100 0.178
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5.5.8 Camshaft Installation
Special tools
Guide sleeve for installation/removal from driving end F6781676 1
Guide sleeve for installation/removal from free end F6780579 1
Centering sleeve for installation/removal from free end F6780582 1
Graduated disc, free end Y4341124 1
Feeler gauge Y20010128 1
Holder 0015890321/00 1
Material
Engine oil
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
CAUTION
Check camshaft ( Page 374).
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Camshaft Installation
1. Attach outer guide sleeve (1) at driving end
of crankcase and center carefully to camshaft
bearings with inner guide sleeve (2).
2. Center guide flange (1) with guide sleeve (2) on
crankcase (free end) with regard to camshaft
bearings and secure.
3. Mount inner guide sleeve (2) on front face of
camshaft (1) and tighten.
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4. Attach camshaft (arrow) with rope at center
to crane and wipe.
5. Spray camshaft, camshaft bearing, and guide
sleeve with engine oil.
6. Install sliding block at outermost cam on camshaft.
7. Carefully insert camshaft up to second-last
bearing.
8. Position assembly extension (1) on camshaft (2)
and insert camshaft up to last bearing.
9. Locate camshaft axially and/or ensure that it
cannot fall out until thrust bearing is installed.
10. Remove inner/outer guide sleeve and assembly
extension.
Installing camshaft thrust bearing
1. Coat axial sliding surfaces with engine oil.
2. Cover bottom of equipment carrier so that no
screws can fall into crankcase.
3. Tighten thrust bearing flange (1) with screws (2).
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Installing locating device
1. Turn camshaft until locating bore (arrow), driving
end, is visible and at position shown.
2. Position locating device (1) on securing plane of
swing-follower shaft, driving end.
3. Insert dowel pin of guide tube (3) into camshaft
bore (2) and screw locating device into place
(arrows).
Installing timing wheel (camshaft gear)
2. Install graduated disc (1) with barring tool on
crankshaft. Set to TDC mark of A1 and tighten.
3. Set piston A1 to firing TDC ( Page 315).
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objects can fall into crankcase.
5. Insert camshaft gear (1) into camshaft so that
dowel pins (3) engage in camshaft gear bore in
a vertical line.
6. Slide timing wheel (2) over dowel pins (3) and
install.
7. Screw in screws (4) with spring washers and
tighten ( Page 80). Note position of holes of
dowel pins to screw bores.
Measuring backlash
1. Remove camshaft locating device.
on crankcase (free end).
3. Mount dial gauge stylus with low preload on one
tooth flank of camshaft gear.
5. Check backlash by moving camshaft gear back
and forth. Circumferential backlash ( Page 199).
Measuring camshaft axial clearance
2. Fit dial gauge stylus on timing wheel.
3. Press camshaft on camshaft gear axially as
far as it will go.
4. Set dial gauge with preload to zero.
5. Move camshaft from stop to stop and record
measurement value (axial clearance). Axial
clearance ( Page 377)
6. If axial clearance is out of tolerance, replace thrust
bearing ( Page 394).
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Installing speed sensor
1. Coat O-ring with petroleum jelly.
2. Turn speed sensor (2) slightly to install in
crankcase fit.
3. Screw in screw (1) and tighten.
Checking speed sensor clearance
1. Pull camshaft on camshaft gear axially toward free
end (arrow) as far as it will go.
2. Measure distance (X) with feeler gauge (specified
value 0.3 mm to 1 mm).
3. If distance is less than 0.3 mm:
3.1. Fit appropriate number of adjusting shims of
0.3 mm thickness.
3.2. Measure distance.
Checking camshaft timing
1. Determine TDC position of piston in the following
way:
1.1. Install measuring device (2) with dial
gauge (1) at cylinder head A1.
1.2. Fit TDC mark (graduated disc) on crankshaft
journal, free end.
1.3. Install suitable TDC pointer on equipment
carrier or crankcase, driving end.
1.4. Using the barring tool, bar the engine until
the piston of cylinder A1 is in the firing TDC.
The piston is at firing TDC when both rocker
arms are unloaded, i.e. have clearance.
2. Move piston up and down several times and then
position so that pointer on dial gauge shows its
maximum reading.
4. Rotate crankshaft against normal direction of
rotation by approx. 10.
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5. Set crankshaft in direction of rotation to 0.3 mm
(dial gauge indicator) before TDC.
6. Apply exact line marking on graduated disc, driving
end, or crankshaft journal, free end, opposite
TDC pointer tip.
7. Bar crankshaft in direction of rotation approx. 10
past TDC (to take up bearing clearance).
8. Bar crankshaft in direction opposite to normal
direction of rotation to 0.3 mm after TDC and
make a second mark. To prevent measurement
errors caused by bearing clearance, the piston
must move in direction of TDC.
9. Apply third mark at exact center between marks.
10. Align graduated disc so that mark for cylinder A1
corresponds to pointer.
11. Check TDC position.
12. Remove measuring device with dial gauge.
Measuring valve lift
1. Set cylinder A1 to firing TDC.
2. Release locknuts on adjusting screw.
3. Screw in adjusting screws until there is no longer
clearance.
4. Lightly tighten locknuts.
5. Mount magnetic-base indicator holder with dial
gauge on cylinder A1.
6. Place dial gauge stylus with slight preload on valve
bridge of inlet valve. Set scale to zero.
7. Slowly turn crankshaft further in direction of engine
rotation 360. Set to exactly overlap TDC (line
marking on graduated disc).
8. Read valve lift from dial gauge and record readings
in Data Sheet.
9. Mount dial gauge stylus on valve bridge of exhaust
valve and set scale to zero.
10. Further rotate crankshaft slowly in engine direction
of rotation until pointer of dial gauge no longer
moves.
in Data Sheet.
12. Check that specified values are
observed. Specified values, see
DM_110_WM_000001_276A.
13. If the specified value is not attained, contact
Service.
14. Remove magnetic-base indicator holder with dial
gauge and TDC indicator.
15. Valve clearance at cylinder A1 (Operating
Instructions).
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5.5.9 Camshaft drive Overview
Camshaft drive Overview
1 Hex screw
2 Spring washer
3 Graduated disc
4 Camshaft gear
5 Hex screw
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5.5.10 Camshaft drive Removal
Special tools
1. Turn engine with barring tool in normal direction
of rotation until TDC mark and arrow on end
housing are aligned.
If rocker arms on cylinder A1 are unloaded, the
piston is in firing TDC.
If rocker arms on cylinder A1 are loaded, the
piston is in overlap TDC.
2. Remove valve drive DM_110_WM_055050_520A.
3. Disconnect electrical plug-in connection.
4. Remove screw (arrow).
5. Turn speed sensor (1) slightly to remove from
crankcase fit.
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swing follower shaft, driving end.
(arrows).
Removing timing wheel (camshaft gear)
2. Remove timing wheel (2) and camshaft gear (1)
from camshaft and dowel pins (3).
3. To protect the crankcase from falling objects, cover
equipment carrier from below.
4. Do not remove locating device.
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5.5.11 Camshaft drive Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Camshaft drive Cleaning
1. Clean all components with cleaner.
3. Blow camshaft drive clear with compressed air.
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5.5.12 Camshaft drive Check
Spare parts
Camshaft gear
Timing wheel
Screw
Spring washer
Camshaft drive Check
Item Findings Task
Check surface condition of tooth
flanks with magnifying glass.
Scores
Stress marks
Indentations
visible
Corrective work
Replace
Check timing wheel and camshaft
gear for damage.
Replace
Check threads of hex bolts for
damage.
Damaged Replace
Check spring washer for damage. Damaged Replace
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5.5.13 Camshaft drive Installation
Special tools
Holder 0015890321/00 1
Material
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
For camshaft drive installation, see section Installing timing wheel (camshaft gear) ( Page 379).
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5.5.14 Camshaft thrust bearing Overview
Overview of camshaft thrust bearing
1 Thrust bearing flange 2 Hex screw
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5.5.15 Camshaft thrust bearing Cleaning
Material
WARNING
WARNING
Compressed air.
Risk of injury!
CAUTION
Camshaft thrust bearing Cleaning
3. Blow thrust bearing clear with compressed air.
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5.5.16 Camshaft thrust bearing Replacement
Material
Engine oil
Spare parts
Thrust bearing flange
Hex screw
Camshaft thrust bearing Replacement
1. Remove camshaft drive ( Page 387).
2. Replace camshaft thrust bearing as shown in overview drawing ( Page 392).
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5.5.17 Camshaft thrust bearing Check
Material
Spare parts
Hex bolts
Camshaft thrust bearing Check
Item Findings Task
Test trust bearing flange for cracks
using surface crack-test method.
Check mating faces, fits and sliding
surfaces for damage.
Replace
Check threads of hex bolts for ease
of movement.
Sluggish Replace
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5.5.18 Valve drive Overview
Rocker arm, swing follower assembly
2 Rocker arm, inlet valve
3 Rocker arm, exhaust valve
4 Adjusting shim
5 Snap ring
6 Valve bridge
7 Hex screw
8 Washer
9 Swing follower, exhaust valve
10 Swing follower, inlet valve
11 Swing-follower shaft
12 Hex screw
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Rocker shaft support
1 Snap ring
2 Adjusting shim
3 Bush
4 Adjusting screw
6 Nut
7 Grooved pin
9 Coiled spring pin
10 Coiled spring pin
11 Sealing plug
12 Axle
14 Thrust pad
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Swing follower
1 Bush
2 Ball seat
5 Roller
6 Bush
7 Pin
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Valve bridge
1 Valve bridge 2 Nut 3 Adjusting screw
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5.5.19 Valve drive Removal
Removing rocker arms
1. Bar crankshaft to bring piston of appropriate
cylinder to firing TDC. The piston is at firing TDC
when both rocker arms are unloaded.
2. Remove screw (1) and remove rocker shaft support
(2) from cylinder head. Ensure that no pushrod is
removed by the suction effect on the ball socket.
3. Mark valve bridges (2) and remove from sliding
pin (3) in cylinder head.
4. Mark pushrods (1) and pull out.
Removing swing followers
2. Remove swing follower shaft with swing followers
(2) from crankcase.
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5.5.20 Valve drive - Disassembly
WARNING
Risk of injury!
Remove valve drive DM_110_WM_055050_520A
Disassembling rocker arm
1. Clamp rocker shaft support in vice with aluminium
jaws.
2. Using snap ring pliers, remove snap ring (2)
from shaft.
3. Remove washer (1).
4. Take off rocker arm (1) from axle.
5. Remove nut (2) and adjusting screw (3).
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6. Secure valve bridge (3) in vice with aluminium
jaws.
7. Slacken nut (1) and remove adjusting screw (2).
Removing swing follower bushing
1. Check whether swing follower bushing must be
removed ( Page 405) .
2. If removal is necessary, use mandrel and hydraulic
press to remove swing follower bushing (2) from
swing follower (1).
Removing pin and roller
1. Check whether pin and roller must be removed
( Page 405) .
2. If removal is necessary:
2.1. Place swing follower between two prisms so
that both sides of pin bore have sufficient
support.
2.2. Use mandrel and hydraulic press to pin
(1) from swing follower (2).
2.3. Remove roller (3) from installation position.
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Removing exhaust rocker arm bushing
1. Check whether rocker arm bushing must be
press to remove rocker arm bushing (1) from
exhaust rocker arm (2).
Removing inlet rocker arm bushing
1. Check whether rocker arm bushing must be
press to remove rocker arm bushing (1) from
inlet rocker arm (2).
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5.5.21 Valve drive Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning the valve drive
2. Thoroughly blow out all parts with compressed air.
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5.5.22 Valve drive Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Holder 0015890321/00 1
Material
Crack testing oil (Nr. 63) 40475 1
Crack testing paste (UV-Apelux Paste 1031) 40483 1
Spare parts
Snap ring
Lockwasher
Bearing bushing
Swing follower
Swing follower shaft
Valve bridge
Roller
Pushrod
Hex screw
Adjusting screw
CAUTION
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Checking valve drive
Item Findings Task
Using the magnetic crack-testing
method, check the following
components for cracks.
Rocker shaft support and axles
Rocker arms
Valve bridges
Swing followers
Roller
Pin
Pushrods
Hex screws
Adjusting screws
Cracks visible Replace
Check running surfaces of axles,
rollers, valve bridges and rocker
arms for wear, indentations and
scoring.
Wear
Indentations
Scores
visible
Recondition
Replace
Check mating faces on rocker shaft
support.
Damaged Recondition
Replace
Check snap ring grooves of axles
for condition.
Damaged Recondition
Replace
Check ball element. The ball
element must not jam within the
swivel angle, on all sides at least
10, and must move freely.
Sluggish Replace
Check screws, nuts and adjusting
screws for damage.
Damaged Replace
Check pushrod concentricity. Out-of-round Replace
Measuring diameter of bushing bore in rocker arm
1. Adjust bore gauge to basic size of bushing
bore and measure diameter of bore. Values
( Page 408).
2. If limits are exceeded, replace bearing bushing.
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Measuring diameter of rocker shaft support axles
1. Using outside micrometer, measure outside
diameters of bearings. Values ( Page 408).
2. If values are not attained, replace rocker shaft
support.
Measuring swing follower bushing bore
1. Adjust bore gauge to basic size of bushing bore
and measure diameter of bore.
Values ( Page 408).
3. Replace gaskets and sealing washers.
4. Make sure that oil bores are perfectly clean and
free of obstruction.
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5.5.23 Valve drive Tolerances
Rocker shaft support, inlet and exhaust
Deviation Clearance Interference No. Designation Repair
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
Rocker arm bore 50.000
H7
0 +0.025 1
Bush OD 50.000
s6
+0.043 +0.059
0.018 0.059
Bush bore
installed 45.000 0 +0.050
removed 45.000
E6
+0.050 +0.066
2
Rocker shaft OD 45.000
f6
0.041 0.025
max.
0.100
Rocker shaft
support bore
45.000
U7
0.086 0.061 3
f6
0.041 0.025
0.020 0.061
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Swing follower support, inlet and exhaust
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
Swing follower
bore
36.000
H7
0 +0.025 1
Bush OD 36.000
s6
+0.043 +0.059
0.018 0.059
Bush bore
installed 32.000 0 +0.050
removed 32.000
E6
+0.050 +0.066
2
Shaft OD 32.000
f6
0.041 0.025
max.
0.100
Roller bore 21.000
E7
+0.040 +0.061 3
Bush OD 21.000
H7
0.021 0
max.
0.090
Bush bore 14.000
E7
+0.032 +0.050 4
Pin OD 14.000
h5
0.008 0
max.
0.065
Swing follower
bore
14.000
P6
0.026 0.015 5
Bush OD 14.000
h5
0.008 0
0.007 0.026
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5.5.24 Valve drive Assembly
Material
Liquid nitrogen
Engine oil
DANGER
WARNING
Compressed air.
Risk of injury!
WARNING
Component is hot.
Risk of burning!
WARNING
Risk of injury!
CAUTION
Assembling rocker arm
1. Clamp rocker shaft support in vise with aluminum
jaws.
2. Insert adjusting screw (3) into rocker arm (1).
3. Screw nut (2) onto adjusting screw but do not
tighten.
4. Coat axles on rocker shaft support and bushes
of rocker arm with engine oil.
5. Fit rocker arm on axle.
6. Install second rocker arm similarly.
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7. Fit washer (1) and secure with snap ring (2).
8. Check whether snap ring is correctly seated.
9. Check minimum thrust distance of rocker arm.
10. Screw adjusting screw (2) into valve bridge (1).
11. Screw nut (3) onto adjusting screw, but do not
tighten.
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Assembling swing followers for inlet and exhaust
1. Chill bushes (2) in liquid nitrogen and press fit in
swing follower (1) on both sides.
2. Observe bush clearance (A) of 0.5 mm 0.5 mm.
3. Heat swing follower to approx. 130 C to 150 C.
4. Insert roller (3) in swing follower.
5. Chill pin (1) in liquid nitrogen. Insert flush by hand
into swing follower (2). Subsequent pressing is
not permissible.
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Assembling rocker arm
1. Chill bush (1) in liquid nitrogen.
2. Heat exhaust rocker arm (2) to approx. 200 C.
3. Insert bush so that it is flush. Protrusion is not
permissible.
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5.5.25 Valve drive Installation
Special tools
Box wrench, 19 mm F30028351 1
Material
Engine oil
WARNING
Compressed air.
Risk of injury!
CAUTION
Adjusting and mounting valve bridges
1. Measure sliding pin protrusion from cylinder
head surface.
2. Clamp valve bridge (1) in vise with aluminum jaws.
Loosen locknut (2) and back off adjusting screw (3)
by approx. three turns.
3. Check oil bores of valve bridges with compressed
air.
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4. Fit valve bridges on sliding pin in cylinder head in
accordance with the marking (installation position).
Adjusting screws must face charge air pipe.
5. Press down valve bridge and hold. Valve bridge
must contact valve stem (a).
6. With the valve bridge depressed, screw in
adjusting screw (arrow) with Allen key until
adjusting screw is slightly in contact with valve
stem and a thrust point can be felt.
7. Check clearance between valve bridge and valve
stem. Use a second feeler gauge (b) to check the
clearance at the opposite valve stem. Clearance
is adjusted correctly if a 0.05 mm feeler gauge
just passes the gap.
8. Hold adjusting screw with Allen key and fit locknut
on valve bridges by hand.
9. Remove valve bridge.
10. Clamp valve bridge (1) in vise with aluminum jaws.
11. Use torque wrench to tighten locknut (2) to
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12. Fit valve bridge(s) on sliding pin in cylinder head in
accordance with the marking (installation position).
13. Check clearance between valve stem and valve
bridge (arrow) using a feeler gauge (0.05 mm).
14. Coat axle and bushes of swing followers with
engine oil.
15. Fit exhaust and inlet swing follower on swing
follower shaft, ensuring they are correctly
positioned (arrows).
16. Coat rollers and camshaft with engine oil.
17. Match swing followers to left and right cylinder
banks and carefully insert into camshaft chamber.
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19. Ensure correct position of installation (arrow).
Installing pushrods
1. Coat ball seats and ball heads of pushrods with
engine oil.
2. Insert pushrods (2) through cylinder head into ball
seat of swing follower.
3. For pushrods with collar: Fit tab washer (1).
Installing rocker arm
1. Release nuts (2) of adjusting screws (3) on rocker
arm (6) and back off adjusting screw.
2. Place rocker shaft support onto cylinder head.
Take care not to damage fit of notched pins.
3. Check position of ball joints in pushrods (1).
4. Take off tab washer, if fitted.
5. After initial assembly and after extended
out-of-service period: Fill adjusting screws with
engine oil (arrow).
6. Insert screw (4) with washer (5) into the cylinder
head and use torque wrench to tighten to the
specified torque ( Page 80).
7. Adjust valve clearance (Operating Instructions).
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5.5.26 Cylinder head cover Overview
1 Seal
2 Cylinder head cover
3 Screw
4 Washer
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5.5.27 Cylinder head cover Removal
Cylinder head cover Removal
1. Remove screws.
2. Remove cylinder head cover and seal.
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5.5.28 Cylinder head cover Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cylinder head cover Cleaning
1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then flush with cleaning agent (Hakupur 312).
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5.5.29 Cylinder head cover Check
Special tools
Oilstone 8205893261/00 1
Spare parts
Cylinder head cover
Screw
Checking the cylinder head cover
Item Findings Action
Check cylinder head cover for
damage.
Damaged Corrective work: Smoothen
with emery cloth or oilstone.
Replace
Check threads of screws for ease of
movement.
Replace
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5.5.30 Cylinder head cover Installation
Material
Engine oil
Spare parts
Seal
Screw
Washer
CAUTION
Cylinder head cover Installation
1. Install cylinder head cover with seal.
2. Tighten screws.
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5.6 High Pressure Fuel System
5.6.1 HP fuel system Overview
1 Injector
2 HP fuel line
3 HP accumulator
4 Pressure-relief valve
5 HP fuel line, left engine side
6 HP fuel pump
7 HP fuel line, right engine side
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5.6.2 HP pump Overview
1 HP pump
2 Screw
3 Washer
4 Washer
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Front view of HP pump
1 HP line to right-hand engine side
2 Temperature sensor
3 HP line to left-hand engine side
4 HP sensor
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5.6.3 HP pump Removal
Special tools
Lifting equipment for HP pump T80091799 1
Hot-air gun 0005388520 1
WARNING
Fuels are combustible.
Risk of fire and explosion!
Do not smoke.
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
HP pump Removal
1. Install lifting equipment for HP pump (1).
3. Remove HP pump (1).
4. Seal all openings with suitable covers.
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6. Heat intermediate piece (2) to approx. 130C to
free up screw locking compound.
7. Remove intermediate piece (2).
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5.6.4 High-pressure pump Disassembly
This assembly is a replacement part (Reman). It is available within the scope of the service-exchange scheme.
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5.6.5 High-pressure pump Check
Spare parts
High-pressure pump
Screw
High-pressure pump Check
Item Findings Task
Check connection thread on
high-pressure pump for damage.
No ease of movement Recondition
Replace
Check drive gear for damage. Damaged Replace high-pressure pump.
Check wiring for damage. Damaged Replace wiring.
Check sealing faces for damage. Damaged Recondition
Replace
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5.6.6 HP pump Installation
Special tools
Material
Engine oil
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
CAUTION
CAUTION
HP pump Installation
1. Remove all covers prior to installation.
2. Coat thread of intermediate piece (3) with screw
locking compound.
3. Screw intermediate piece (3) into shaft (2).
4. Coat O-ring (1) with grease and insert in groove.
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6. Insert HP pump (1) into bore.
7. Insert screws (2) and tighten.
8. Remove lifting equipment from HP pump.
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5.6.7 H.P. fuel pump Control block replacement
Preconditions
Special tools
Connector pliers 0135315483 1
Material
Engine oil
Spare parts
Control block
O-ring
Connector
WARNING
Do not smoke.
Removing control block
1. Remove fuel line (5) from control block (4). Collect
emerging fuel.
2. Release bayonet lock using pliers and disconnect
connector (6) from magnet.
connector (1) from sensor.
4. Remove sensor (1).
5. Remove screws (3) from control block (4).
6. Remove control block (4) from H.P. fuel pump (7).
Installing control block
1. Coat O-ring with engine oil and insert into groove.
2. Screw control unit (4) with screws (3) onto H.P. fuel pump (7) and tighten to specified torque ( Page 80) .
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3. Connect connector (6) to magnet and tighten bayonet lock using pliers.
4. Coat O-ring of sensor with petroleum jelly.
5. Screw sensor (1) into bore by hand.
6. Tighten nut (2) with torque wrench to specified tightening torque ( Page 80) .
7. Connect connector to sensor (1) and tighten bayonet lock using pliers.
8. Attach fuel line (5) to control block (4).
9. Vent fuel lines.
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5.6.8 Injector Overview
Injector Overview
1 Hold-down clamp
2 Hex screw
3 O-ring
4 Injector
5 O-ring
6 CE-ring
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5.6.9 Injector Removal
Special tools
Puller F30377769 1
Puller bracket F6557991 1
WARNING
Do not smoke.
Remove injector
1. Remove H.P. line (2).
2. Remove screw (1) from hold-down clamp (2).
3. Take off hold-down clamp.
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4. Place puller (4) on injector (1).
5. Turn locking sleeve (2) of puller (1) from position
"a" to position "b".
6. Secure locking sleeve with nut.
7. Place puller bracket (2) on cylinder head.
8. Screw in threaded rod (3) in puller (5).
9. Secure nuts (4).
10. Withdraw fuel injector by turning nut (1) to the right.
11. Remove special tool.
12. Remove puller bracket and locking sleeve.
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13. Remove fuel injector.
14. Remove O-rings (2) from injector.
15. Remove sealing ring (1) from injector or use wire
hook to remove from cylinder head.
16. Seal all connections and installation bores with
covers or plugs.
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5.6.10 Fuel injector disassembly
This component is an exchange component (Reman) and is available through the usual exchange procedure.
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5.6.11 Injector Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
WARNING
CAUTION
Injector Cleaning
2. Dry all components using compressed air.
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5.6.12 Injector Check
Material
Crack testing oil (NR. 63) 40475 1
Spare parts
Fuel injector
Hold-down clamp
Screw
Check injector
Inspect fuel injector externally for
damage.
Damaged Replace
Check screws and hold-down
clamp for cracks with magnetic
Indication of cracks Replace
Check contact surfaces of hold-down
clamp.
Damaged Rework: smooth with oilstone.
Replace
Inspect sealing cone of fuel injector
for damage.
Damaged Replace injector.
Check cable connections for
damage.
Damaged Replace wiring harness.
Check thread on screw and injector
valve for ease of movement.
Sluggish Rework
Replace
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5.6.13 Injector Installation
Special tools
Lever F6555197 1
Force-in lever F6557952 1
Material
Engine oil
Grease (Retinax EP2) 40388 1
Spare parts
O-rings
Sealing ring
WARNING
Do not smoke.
Check injector ( Page 440).
Injector Installation
1. Coat O-rings with petroleum jelly.
2. Fit O-rings on fuel injector.
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3. Use Retinax EP2 grease to fit sealing ring on
mating face of injector.
4. Fit sealing ring on injector so that the even contact
surface faces injector.
5. Insert fuel injector (1) in cylinder head. Ensure
that injector is correctly aligned with H.P. fuel
line connection.
6. Fit force-in tool (2).
7. Lock force-in lever (1) of forces-in tool between
the pushrods.
8. Release palm grip (3) and move pressure element
(2) to correct position for force-in tool.
9. Secure palm grip and press injector (4) with
force-in lever into cylinder head.
10. Remove force-in tool.
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11. Fit hold-down clamp (2) in correct position by hand.
Note: Tighten screw of hold-down clamp only
after connecting the H.P. line.
12. Hand-tighten screw (1) so that the injector is
still rotatable.
13. Install H.P. lines between connecting piece and
injector ( Page 459).
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5.6.14 High-pressure line Overview
HP line from HP accumulator to injector
1 Hold-down clamp
2 Cable connection
3 Injector
4 Filter element
5 Fuel return line
6 HP line
7 Fuel collecting line
8 Limiting valve
9 HP accumulator
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HP line from HP pump to HP accumulator
1 HP line, left side
2 HP line, right side
3 Retainer
4 Pipe half-clamp
5 Screw
6 Retainer
7 Pipe half-clamp
8 Screw
9 Grommet
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HP accumulator and add-on components
1 HP accumulator
2 Thrust element
3 Thrust element
4 Thrust screw
5 O-ring
7 Adapter
8 Thrust screw
9 Connecting piece
10 Screw
11 Limiting valve
12 HP line
13 O-ring
14 Plug-in pipe
15 Sealing ring
16 Plug
17 Plug-in pipe
18 Plug-in pipe
19 Plug-in pipe
20 Plug-in pipe
21 Screw
22 Washer
23 O-ring
24 O-ring
25 O-ring
26 Snap ring
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HP accumulator, left engine side
1 O-ring
2 Thrust screw
3 Thrust element
4 Adapter for HP line
5 Telltale bore
6 Plug-in pipe
7 Thrust element
8 Screw
9 Thrust element
10 Plug-in pipe
11 Plug screw (telltale bore)
12 HP accumulator
13 O-ring
14 Plug-in pipe
HP accumulator, right engine side
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1 Screw
3 Plug-in pipe
5 O-ring
6 Telltale bore
7 Plug-in pipe
8 HP line
9 O-ring
10 Thrust screw
11 Thrust element
12 HP accumulator
14 Plug-in pipe
15 Thrust element
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5.6.15 HP fuel line Removal
Special tools
Crowfoot box wrench for HP lines F30373588 1
WARNING
Do not smoke.
Removing HP line between HP pump and HP accumulator
Note: Prior to removing HP lines, it is advisable to take photographs of all fitted lines or to identify lines
with metal tags.
1. Release threaded union on HP lines and catch fuel emerging.
2. Remove HP fuel lines as per overview drawings ( Page 444).
3. After removal of the lines, seal all connections with suitable plugs.
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Removing HP fuel lines
1. Remove HP lines between injector and HP
accumulator on injector side (arrow).
accumulator on HP accumulator side (arrow).
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Removing HP accumulator
1. Remove fuel return line (1) on HP accumulator of
right engine side, driving end.
2. Remove pressure relief valve.
3. Withdraw plug-in pipe end section (2) and remove
O-ring.
4. Remove limiting valves (2) from connecting
pieces (3).
5. Withdraw plug-in pipe end section (1) from left HP
accumulator.
6. Carefully remove HP accumulator from connecting
pieces and plug-in pipes.
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7. Remove screws (4) from connecting piece (2)
and take off together with plug-in pipe (1) from
crankcase.
8. Remove O-ring (3) from connecting pieces.
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5.6.16 HP fuel line Disassembly
Special tools
Retaining device for HP accumulator installation F6553674 1
WARNING
Heavy object.
Risk of crushing!
Remove HP fuel line ( Page 449).
Disassembling HP accumulator
1. Use retaining device (arrow) to clamp HP
accumulator in vice.
2. Unscrew thrust screw.
3. Remove thrust pad and pressure relief valve.
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5.6.17 HP fuel line Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
HP fuel line Cleaning
2. Thoroughly blow all parts clear with compressed air.
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5.6.18 H.P. fuel line Check
Material
Fluorescent magnetic powder for magnetic crack-testing procedure
Spare parts
H.P. accumulator
Pressure-relief valve
Plug-in pipe
Thrust pad
Limiting valve
Disassemble H.P. fuel line ( Page 453).
H.P. fuel line Check
Item Findings Task
method, check H.P. accumulator for
cracks.
Signs of cracks Replace pressure accumulator.
Check all threads for ease of
movement.
Sluggish Recondition: recut threads.
Replace
Check sealing tapers on thrust pads
for damage.
Damaged Replace
Check sealing cone of pressure
accumulator for damage and wear.
Damage
Wear
visible
Replace
Check that H.P. lines, plug-in pipes
and fuel return line are in perfect
condition.
Damaged Recondition
Replace
Check that H.P. lines and H.P.
accumulator are perfectly clean.
Contaminated Clean ( Page 454)
For checking limiting valves
and pressure relief valves, see
Manufacturers Documentation.
Damaged Contact Service.
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5.6.19 HP fuel line Assembly
Special tools
Material
Molykote G-n plus 40041 1
Engine oil
Spare parts
O-ring
Snap ring
Sealing ring
Washer
A Thrust element with thrust ring (X = 15.5 mm)
B Thrust element without thrust ring (Y = 23.5 mm)
Thrust element, alternatives A and B
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Pressing on thrust ring - Variant A only
1. Degrease and dry thrust element surfaces.
2. Coat surface (arrowed) with oil.
3. Press-fit thrust ring (2) with supporting washer (3)
on thrust element (1).
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Assembling HP fuel line, alternatives A and B
1. Coat mating surfaces between thrust screw and
thrust element as well as between thrust screw
and adapter with Molykote G-n plus.
2. Push thrust screw (1) onto thrust element (2).
3. Coat threads (arrowed) and taper (arrowed)
with engine oil.
4. Preassemble HP accumulator:
4.1. Use retaining device to clamp HP
4.2. Insert prepared thrust pieces with thrust
screws as well as adapter and thrust screw
for pressure-relief valve ( Page 444)in
seating bore and tighten with torque
wrench to the specified tightening torque
( Page 80).
4.3. Install pressure relief valve, and insert but
do not tighten socket-head screws.
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5.6.20 HP fuel line Installation
Special tools
Alignment tool for HP accumulator F6557185 2
Slotted nut screwdriver F30379005 1
Material
Engine oil
Spare parts
O-ring
Gasket
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
CAUTION
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Preparing connecting pieces
2. Insert O-rings in grooves (arrowed) on connecting
piece.
Installing HP accumulator on crankcase
1. Fit connecting pieces and plug-in pipes together in
alternating sequence.
Note: Align plug-in pipes with leak check outlet
facing downwards
2. Fit plug-in pipes over connecting piece O-rings.
3. Insert screws (arrows) for attaching the connecting
piece to the crankcase.
4. Insert HP accumulator in preassembled connecting
piece and plug-in pipe assembly.
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5. Insert alignment tools in tightened connecting
pieces (first and last connecting piece of respective
engine side).
6. Align HP accumulator until alignment tool taper is
centered in bore of HP accumulator.
7. Tighten alignment tool to 20 Nm +2 Nm.
8. Insert limiting valve into outlet openings (arrowed)
of all connecting pieces.
9. If injectors have been removed, they must be
installed first ( Page 441).
10. Using a slotted nut screwdriver, tighten thrust rings
(2) at the thread end to 10 Nm.
Result: Distance of pipe end to thrust ring A =
11.7 mm.
11. Coat O-rings with grease and insert in grooves.
12. Pretighten HP lines between limiting valve and
injector to 5 to 10 Nm.
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13. Use torque wrench to fasten HP lines to the limiting
valves (2) and tighten to specified tightening
torque ( Page 80).
14. Use torque wrench to fasten HP lines to the
injectors (1) and tighten to specified tightening
torque ( Page 80).
16. Insert remaining limiting valves and tighten HP
lines as described.
17. Use torque wrench to tighten hold-down clamp with
screw to specified tightening torque ( Page 80).
18. Use torque wrench to tighten all screws for
attaching connecting pieces to the crankcase to
19. Complete HP accumulator ( Page 444).
20. Remove all plugs (arrow).
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21. Coat thread and screw heads (3) with oil.
22. Install pressure relief valve (2) and fit screws (3)
evenly by hand.
23. Install return line (1) between fuel collecting line
and pressure relief valve.
24. Pressure relief valve:
Variant A
Use torque wrench to tighten 3 screws (3) to
Variant B
Tighten 6 screws (3), spherical washers and
conical sockets crosswise in stages to specified
tightening torque ( Page 80).
Installing HP line between HP pump and HP accumulator
1. Blow out HP lines with compressed air.
2. Install HP lines and securing hardware as per overview drawing ( Page 444) or according to photos/markings,
ensuring that the connections are free of tension.
3. Leak test fuel system (high-pressure) ( Page 464).
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5.6.21 H.P. fuel system Leak check
WARNING
Compressed air.
Risk of injury!
Checking common rail system for leaks
1. Remove pressure sensor (1) from high-pressure
pump (2).
2. Install H.P. inspection line and apply pressure to
system. Test pressure: 3 bar
3. Fit control screws (arrow) on H.P. accumulator.
4. Check all threaded connections in system for leaks.
5. Again remove H.P. testing line from high-pressure
pump.
6. Insert pressure sensor on H.P. pump and tighten to
specified torque with torque wrench ( Page 80) .
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5.7 Low Pressure Fuel System
5.7.1 Fuel system Overview
Fuel system
1 Fuel service tank
2 Non-return flap
3 Fuel prefilter
4 Fuel delivery pump, electric
motor drive
5 Non-return flap
6 Fuel filling connection
7 Connection, fuel supply to engine
8 Fuel hand pump
9 Fuel delivery pump with pressure
relief valve
11 Connection, fuel return from engine
12 Measuring point, fuel pressure
after filter
after H.P. pump
14 Measuring point, fuel temperature
after fuel H.P. pump
15 Jacketed pipe
16 Connection, leak-off fuel return
from jacketed fuel line
17 H.P. accumulator
18 pressure relief valve
19 Injector
20 H.P. fuel pump
21 Connection, return from fuel
prefilter
22 Connection, supply to fuel prefilter
23 Fuel filter
24 Non-return valve after fuel
delivery pump
25 Fuel ventilation
26 Fuel restrictor
27 Overflow valve, fuel return
from engine
from engine
29 Connection for leak-off fuel return
30 Leak-off fuel tank
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5.7.2 Fuel delivery pump Overview
Fuel delivery pump Overview
1 Fuel delivery pump
2 Coupling element
3 O-ring
4 Hex bolt
5 Washer
6 Hex bolt
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5.7.3 Fuel delivery pump Removal
Preconditions
WARNING
Do not smoke.
Removing fuel delivery pump
1. Remove fuel delivery pump as per overview drawing ( Page 466).
2. Remove coupling element from the drive shaft of the fuel delivery pump.
3. Remove O-ring.
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5.7.4 Fuel delivery pump Disassembly
Remove fuel delivery pump ( Page 467).
Disassembling fuel delivery pump
In the event of wear or a complaint, the fuel delivery pump must be replaced.
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5.7.5 Fuel delivery pump Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Fuel delivery pump Cleaning
2. Blow all parts clean thoroughly with compressed air.
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5.7.6 Fuel delivery pump Check
Spare parts
Fuel delivery pump
Screw
Coupling
WARNING
Do not smoke.
Fuel delivery pump Check
Item Findings Task
Perform external check of fuel
delivery pump for perfect condition.
Damaged Replace fuel delivery pump
Check coupling for stress marks and
damage.
Damaged Replace coupling
Check driver of pump shaft for wear. Damaged Recondition: Smooth with
Refer to manufacturers
documentation when replacing
the driver.
Check threads of securing screws. Damaged Replace
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5.7.7 Fuel delivery pump Installation
Material
Grease (Kluthe Hakuform 3010/Emulgier) X00029933 1
Engine oil
Spare parts
O-ring
WARNING
Do not smoke.
Fuel delivery pump Installation
2. Mount coupling element (2) on driver.
3. Align fuel delivery pump driver to coupling element.
4. Carefully insert fuel delivery pump in bore
and install as shown in overview drawing
( Page 466).
5. If the pump cannot be inserted up to the stop,
remove the pump again and check the position of
the driver to the coupling element.
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1
WARNING
Do not smoke.
Fuel delivery pump Removal
1. Switch off fuel delivery pump and disconnect from power supply.
2. Remove fuel lines.
3. Collect emerging fuel in a suitable container.
4. Remove securing screws from fuel delivery pump.
5. Remove fuel delivery pump.
6. Seal all openings on the engine.
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Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
CAUTION
1. Clean all components using cleaning agent.
2. Remove cleaning agent.
3. Blow off all parts thoroughly with compressed air.
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WARNING
Do not smoke.
Clean fuel delivery pump ( Page 474).
1. Open connections on engine.
2. Mount fuel delivery pump on foundation with securing screws.
3. Install fuel lines.
4. Connect fuel delivery pump to power supply.
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5.7.12 Fuel pipework from fuel delivery pump to fuel filter Overview
1 Plug-in pipe
2 O-ring
3 Flange
4 Non-return valve
5 O-ring
6 O-ring
7 Screw
8 Washer
9 Plug-in pipe
10 O-ring
11 Flange
12 Flange
13 O-ring
14 Screw
15 Washer
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5.7.13 Fuel lines from fuel delivery pump to fuel filter Removal
Preconditions
WARNING
Do not smoke.
Removing fuel lines from fuel delivery pump to fuel filter
1. Before removing the lines, take photos or label add-on components and lines.
2. Disconnect fuel line and collect escaping fuel.
3. Remove fuel lines from fuel delivery pump to fuel filter as shown in overview drawing ( Page 476).
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5.7.14 Fuel lines from pump to filter Cleaning
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove fuel lines ( Page 477).
Cleaning fuel lines
1. Clean fuel lines and non-return valve with cleaning agent.
3. Thoroughly blow out fuel lines and non-return valve with compressed air.
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5.7.15 Fuel lines from fuel delivery pump to fuel filter Check
Spare parts
Non-return valve
Flange
Plug-in pipe
WARNING
Risk of injury!
Fuel lines from fuel delivery pump to fuel filter Check
Item Findings Task
Visually check plug-in pipes, flanges and
non-return valve for damage and wear.
Damaged Replace
Check plug-in pipes for leaks with air
in water bath as necessary. A water
temperature of min = 30 C or max = 40 C
and a test pressure of 0.5 bar must be
maintained.
Leaking Replace
Check non-return valve for leaks and
check opening pressure.
Leaking
Opening pressure
incorrect.
Replace
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5.7.16 Fuel lines from fuel delivery pump to fuel filter Installation
Material
Spare parts
O-ring
WARNING
Do not smoke.
CAUTION
Fuel lines from fuel delivery pump to fuel filter Installation
2. Install O-rings on plug-in pipes and coat with grease.
3. Install fuel lines as per overview drawing ( Page 476).
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5.7.17 Fuel duplex filter Overview
1 Valve (0.5 bar)
2 Plug screw
3 Plug screw
4 Valve (1 bar)
5 Plug screw
6 Threaded union
7 Fuel line
8 Plug screw
9 Screw
10 O-ring
11 Fuel hand pump
12 Plug screw
13 Threaded union
14 Blanking cone
15 Nut
16 O-ring
17 Elbow
18 Screw
19 Threaded nipple
20 Easy-change fuel filter
21 Threaded nipple
22 Plug screw
23 Plug screw
24 Filter head
25 Threaded union
26 Blanking cone
27 Nut
28 Threaded union
29 Threaded union
30 O-ring
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5.7.18 Fuel duplex filter Removal
Preconditions
Special tools
Filter wrench F30379104 1
WARNING
Do not smoke.
Fuel duplex filter Removal
1. Remove filter elements using filter wrench (1).
2. Collect emerging fuel.
3. Remove filter head as shown in overview drawing
( Page 481).
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5.7.19 Fuel duplex filter Disassembly
WARNING
Do not smoke.
Fuel duplex filter Disassembly
1. Remove and disassemble hand pump as shown in overview drawing ( Page 481).
2. Disassemble filter head as shown in overview drawing.
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5.7.20 Fuel filter Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Fuel filter Cleaning
3. Thoroughly blow out all parts using compressed air.
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5.7.21 Fuel filter Check
WARNING
Risk of injury!
Checking fuel filter
Visually inspect filter head and hand
pump for damage and condition
Damaged Replace
Check sealing and bolt-on faces for
damage
Damaged Smooth with oilstone
Replace
Check all threads and threaded
holes.
Damaged Rework: recut thread.
Replace
Leak-test filter head using air and
water bath. Install filter elements
before carrying out leak test. Test
temperature: min. 30 C, max.
40 C, if oil filter housing has to be
held in hands. Test pressure: 0.5
bar.
Leaking Replace plugs and sealing
rings
Replace filter head
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5.7.22 Fuel duplex filter Assembly
Material
Engine oil
Spare parts
Plug screw
O-ring
WARNING
Do not smoke.
Fuel duplex filter Assembly
Note: Coat O-rings with grease.
1. Assemble filter head as shown in overview drawing ( Page 481).
2. Assemble hand pump as shown in overview drawing and install on filter head ( Page 481).
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5.7.23 Fuel duplex filter Installation
Material
WARNING
Do not smoke.
Installing fuel duplex filter
1. Remove all plugs.
3. Install fuel duplex filter as shown in overview drawing ( Page 481).
Installing easy-change fuel filter
1. Coat sealing rings (arrow) of filters with fuel.
2. Install filter and tighten by hand.
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5.7.24 Fuel pipework from fuel filter to HP pump Overview
Fuel line
1 Fuel line
2 Union
3 Pipe half-clamp
4 Pipe half-clamp
5 Grommet
6 Washer
7 Screw
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5.7.25 Fuel pipework from fuel filter to HP pump Removal
Preconditions
WARNING
Do not smoke.
Fuel pipework from fuel filter to HP pump Removal
1. Release threaded union on fuel line and catch fuel as it escapes.
2. Remove fuel line with securing hardware as shown in overview drawing ( Page 488).
3. After removal of the fuel lines, seal all connections with suitable plugs.
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5.7.26 Fuel pipework from fuel filter to high-pressure pump Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Fuel pipework from fuel filter to high-pressure pump Cleaning
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5.7.27 Fuel pipework from fuel filter to high-pressure pump Check
Spare parts
Fuel line
Retainer
WARNING
Risk of injury!
Fuel pipework from fuel filter to high-pressure pump Check
Item Findings Task
Visually inspect fuel lines for
damage.
Replace
Pressure-test fuel line with air
in water bath for leaks. A water
temperature of min. = 30 C or
max. = 40 C and a test pressure of
0.5 bar must be maintained.
Leaking Replace
damage.
oilstone.
Replace
Check threads of union nuts
and threaded unions for ease of
movement.
Replace
Check securing elements on fuel
lines for damage.
Damaged Replace
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5.7.28 Fuel pipework from fuel filter to HP pump Installation
Material
Engine oil
Spare parts
Grommet
WARNING
Do not smoke.
CAUTION
CAUTION
Fuel pipework from fuel filter to HP pump Installation
2. Install fuel pipework from fuel filter to HP pump as per overview drawing ( Page 488).
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5.7.29 Leak-off fuel pipework Overview
Fuel return lines
1 Fuel return line
2 Union
3 Sealing ring
6 Union
7 Sealing ring
8 Sealing cone
9 Plug nut
10 Pipe half-clamp
11 Screw
12 Grommet
13 Retainer
14 Grommet
15 Grommet
16 Screw
17 Screw
18 Pipe half-clamp
19 Pipe half-clamp
20 Fuel return line
21 Fuel return line
22 Fuel return line
23 Fuel return line
24 Banjo screw
25 Sealing ring
26 T adapter
27 Fuel return line
28 Fuel return line
29 Grommet
30 Grommet
31 Pipe half-clamp
32 Pipe half-clamp
33 Screw
34 Pipe half-clamp
35 Union
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1 Leak-off fuel housing
2 Screw
3 Washer
4 Adapter
5 Union
6 Sealing ring
7 Plug screw
8 Leak-off fuel line
10 Threaded adapter
11 Sealing ring
12 Sealing cone
13 Nut
14 Retainer
15 Retainer
16 Grommet
17 Pipe half-clamp
18 Pipe half-clamp
19 Screw
20 Pipe half-clamp
21 Pipe half-clamp
22 Screw
23 Grommet
24 Screw
25 Pipe half-clamp
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5.7.30 Leak-off fuel line Removal
Preconditions
WARNING
Do not smoke.
Removing leak-off fuel line
1. Prior to removal of the lines take photos or mark add-on components and lines.
3. Remove fuel lines with securing hardware as per overview drawing ( Page 493).
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5.7.31 Leak-off fuel pipework Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Leak-off fuel pipework Cleaning
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5.7.32 Leak-off fuel pipework Check
Spare parts
Sealing rings
WARNING
Risk of injury!
Leak-off fuel pipework Check
Item Findings Task
Visually inspect all leak-off fuel lines
for damage.
Replace
Pressure-test leak-off fuel lines with
air in water bath for leaks. A water
temperature of min = 30C and
max = 40C and a test pressure of
Leaking Replace
Check banjo screws for damage and
Damaged
Threads sluggish.
Corrective work: Recut threads
Replace
damage
oilstone.
Replace
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5.7.33 Leak-off fuel line Installation
Spare parts
Sealing ring
Grommet
WARNING
Do not smoke.
CAUTION
CAUTION
Installing leak-off fuel line
2. Install leak-off fuel line according to overview drawing ( Page 493) or according to photos/markings.
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5.8 Exhaust Turbocharger
5.8.1 Exhaust turbochargers Overview
Exhaust turbochargers Overview
10 Exhaust turbocharger, left
engine side
11 Exhaust turbocharger, right
engine side
13 Locking plate
14 Adapter
16 Screw
18 Screw
19 Washer
25 Nut
30 Sealing ring
35 Screw
40 Spacer sleeve
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5.8.2 Exhaust turbocharger Removal
Preconditions
Special tools
WARNING
Heavy object.
Risk of crushing!
Exhaust turbocharger Removal
1. Insert eyebolt into bearing housing of exhaust turbocharger.
2. Secure exhaust turbocharger with crane and hook-ended chain sling.
3. Remove nuts and sleeves for exhaust turbocharger as per overview drawing ( Page 499).
4. Remove exhaust turbocharger from exhaust manifold.
5. Remove sealing rings.
6. Remove studs from exhaust manifold.
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5.8.3 Exhaust turbocharger Disassembly
Special tools
Vibe jaw F70144375 2
T torque wrench F30520703 1
Snap ring pliers F30376601 1
WARNING
WARNING
Risk of injury!
Exhaust turbocharger Disassembly
1. Mark positions of compressor casing (1) and
turbine housing (4) to the bearing housing (2) and
to the back wall of the compressor (arrows).
2. Mount turbine housing (4) on the gas intake
flange with braces.
3. Remove tensioning segments (3) from turbine
housing.
4. Carefully take turbine housing (4) off bearing
housing, in doing so do not tilt housing. Tilting
can cause damage to the blade.
5. If the turbine housing (4) sticks, use rust-removing
agent. If necessary, use copper hammer.
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6. Remove nuts (1) and tensioning segments (2) from
compressor casing.
7. Carefully take compressor casing off bearing
housing. Take care that the blade is not damaged.
8. If the turbine housing sticks, use a rubber mallet.
9. Mount impeller on the hub in the vibe jaw (3).
Note: Left-hand thread
10. Remove self-locking nut (2) with two-armed
wrench (1).
11. The nut is only loosened with the two-armed
wrench so that the impeller shaft is not damaged.
12. Pull compressor wheel (1) off compressor shaft, if
necessary press the impeller out with a handpress
(arrow).
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13. Carefully remove impeller shaft (2) from bearing
housing (1).
14. Center heat shield (3) and remove from the
impeller shaft, in doing so observe piston rings.
15. Remove piston rings (1) with pliers from the
impeller shaft.
16. Mount bearing housing between both flange faces
in bench vise (use braces).
17. Remove screws (1), take back wall (2) off bearing
housing and remove O-rings.
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18. Press sealing bushing (1) out of back wall (3).
sealing bushing (1).
20. Remove oil thrower ring (1), oil retainer (2), bearing
collar (3), axial bearing washer (6), bushing (5)
and bearing collar (4) from bearing housing.
21. Install snap rings (1) and bearing bushing (2) at
the compressor side and then remove snap rings
(3) and bearing bushing (4) at the turbine side.
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5.8.4 Exhaust turbocharger Cleaning
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
CAUTION
Disassemble exhaust turbocharger ( Page 501).
Exhaust turbocharger Cleaning
3. Thoroughly blow off all parts with compressed air.
Wet sand blasting
1. Protect bearing bores and piston ring sealing faces on the bearing housing and shaft and piston ring sealing
faces on the back wall from cast-steel shots.
2. Wet sand blast housing, impeller, compressor wheel, back wall and heat shield.
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5.8.5 Exhaust turbocharger Check
Spare parts
Bearing housing
Turbine housing
Compressor housing
Rotor
Compressor wheel
Exhaust turbocharger check
Visually check housing, guide vane
ring, heat shield and impellers for
cracks, foreign objects and scoring.
Cracks
Foreign objects
Scoring
visible
Replace
Check oil supply bores in bearing
housing for foreign objects.
Foreign objects visible. Replace
Check piston sealing faces and
bearing points for damage.
Damaged Replace
Check turbine housing for scaling. Scale visible on gas inlet land or
circumference.
Replace
Check gas inlet flange and gas
outlet flange for flatness.
Flange uneven. Corrective work: Smooth using
oilstone.
Replace
Check impellers for bent or broken
blades and check impeller shaft for
scored bearings.
Damaged Replace
Check piston seat in rear wall and
bearing housing for scoring and
damage.
Scores
Damage
visible
Replace
Self-locking nuts
O-rings
Replace
Wear parts and rotating parts that display cracks must be replaced.
Replace clamping segments, nut, shaft nut, piston rings, cylinder head bolts and washers, O-rings, oil deflector,
thrust washer, snap rings, bearing bushings and screws during overhaul.
Bearing housing
Note: The segment mating faces must not display severe corrosion.
1. Measure max. bore ID at the bearing points using a bore gauge.
Max. bore ID = 22.272 mm
2. If the limit value is exceeded, replace bearing housing.
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Turbine housing
1. Radial cracks of up to 10 mm in length in the area
of lug (2) and partition wall (1) are permissible.
2. Complete cracking is not permissible.
3. Slight scoring in the circumferential area is
permissible.
4. Replace component if the gas inlet flange or gas
outlet flange is distorted.
Compressor housing
1. Check circumferential area (arrowed) for scoring
and deformation. Scoring of up to 0.2 mm
is permissible.
2. Replace compressor housing if deformed.
Rotor
1. Check rotor shaft for roundness:
1.1. Position rotor shaft on two V-blocks at
the bearing points.
1.2. Position measuring sensor on the shaft
at a distance of 5 mm to the end of the
compressor wheel seat.
1.3. Evenly press rotor shaft onto the V-blocks
during testing.
1.4. Maximum permissible radial runout <
0.008 mm.
1.5. Replace rotor if the permissible radial
runout is exceeded.
2. Measure shaft diameter at the bearing points and
piston ring groove width.
Min. diameter = 14.25 mm
Max. groove width = 3.32 mm
3. Replace shaft if limit values are violated.
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Note: During production, all compressor wheels and
shafts are balanced separately. Deposits and
contamination on the compressor and turbine
wheels can lead to unbalance during operation.
Unless a new rotor assembly is installed,
the entire rotor assembly must be balanced
during each repair.
Balancing rotor assembly
1. Clean all parts of the rotor assembly (rotors,
bearing collar, seal bushing (oil deflector ring),
bush, compressor wheel and shaft nut) prior
to balancing.
2. The position of the parts relative to each other
must be marked.
Note: The rotor assembly must only be balanced
in planes A and B!
3. Support rotor assembly at bearing points (arrowed)
in balancing device.
4. Impermissible residual unbalance of the rotor
assembly must be reduced by taking off material
(see following paragraphs) in planes A and B to
the max. values stated in the table.
Turbocharger type Balancing plane A (C) in mmg Balancing plane B (T) in mmg
K 36 4.0 3.1
K 37 4.6 3.6
Removing material at compressor wheel
1. During material removal in the area of the blade
base a minimum distance (X) of 2 mm must
be adhered to.
2. Any hollows must not show edges to the
surrounding area.
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Removing material at turbine wheel
1. Material removal during balancing in a circle
segment of max. 150.
surrounding area.
Max. permissible material removal
Turbocharger
type
Compressor wheel Turbine wheel
D
(mm)
R
(mm)
F
(mm)
G
(mm)
H
(mm)
K 36 4 4 2.5 4.0 1.5
K 37 4 5 2.5 4.0 1.5
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5.8.6 Exhaust turbocharger Tolerances
Admissible contour clearance for K36
Gap clearance between min. (mm) max. (mm)
A Compressor wheel contour 0.35 0.8
B Compressor wheel rear side

C Turbine wheel contour 0.62 1.06
D Turbine wheel rear side 0.8 1.2
Axial clearance 0.08 0.135
Radial clearance, max. with

83 mm distance between
bearings
0.58

bearings
0.68
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B Compressor wheel rear side 0.8


bearings
0.57

bearings
0.72
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5.8.7 Exhaust turbocharger Assembly
Special tools
Assembly jaws F70144375 2.
Tee torque wrench, 10-90 Nm F30520703 1
Angle of rotation measuring device Y20044010 1
Dynamometer Y20504961 1
Material
Engine oil 40453 1
Assembly paste Ultra-Therm MTU 50547 1
Loctite 640 40105 1
Spare parts
O-rings
Spring pins
Piston rings
Bearing bushings
Piston rings
Snap ring
WARNING
Heavy object.
Risk of crushing!
WARNING
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Exhaust turbocharger Assembly
1. Check that all parts are perfectly clean, clean if
required.
2. Oil the following bearing components prior
to installation:
Rotor bearing seats
Bearing bushings
Thrust washer
Sealing bushing
Oil control ring
Bearing collar
Piston rings
Bushing
3. Install snap rings (1) and bearing bushing (2) from
compressor side, then snap rings (3) and bearing
bushing (4) from turbine side in bearing housing.
4. Insert snap rings with the round edge facing the
bearing bushing. Ensure that the snap ring is
properly seated in the groove!
5. Clamp rotor shaft in bench vise (use protective
jaws).
6. Carefully fit piston rings (1) on shaft, aligning the
piston ring joints (arrow) arranged with an offset
of 180.
7. Center piston rings on rotor shaft.
8. Carefully place heat shield (1) over piston rings on
turbine wheel.
9. Insert a sheet strip (2) of 1 mm thickness between
heat shield and rear side of turbine wheel to
ensure that the piston rings are properly guided in
the bearing housing bore.
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10. If the rotor assembly has been rebalanced,
observe the associated position markings.
11. Move sleeve onto rotor shaft to protect the thread.
12. Carefully move bearing housing (4) onto rotor
shaft, ensuring that the oil supply bore of the
bearing housing is arranged with an offset of 90
towards the piston ring joint.
Note: The piston rings are properly seated when
heat shield and bearing housing can
easily be rotated.
13. Move first bearing collar (5) and bushing (2)
onto rotor shaft.
14. Insert thrust washer (3) in bearing housing,
ensuring that the centering pins (arrows) are
properly seated.
15. Move second bearing collar (1) onto rotor shaft.
16. Place oil baffle plate (1) on thrust washer, ensuring
that the oil baffle plate is properly seated (arrows).
17. Move oil control ring (3) with smaller collar facing
downwards onto rotor shaft.
18. Coat new O-ring (2) with petroleum jelly and insert
in groove in bearing housing.
19. Carefully install two piston rings (2) on sealing
bushing (1).
20. Arrange piston ring joints with 180 offset.
21. Install sealing bushing with chamfer (arrow)
facing compressor wheel rear side (upwards) in
rear wall (3).
Note: If necessary, compress piston ring with
screwdriver.
22. Position sealing bushing so that oil supply bore
of bearing housing is arranged at 90 offset
towards piston ring joint.
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23. Clean threads of screws (1) and in bearing
housing, ensuring that they are free of grease
and dry.
24. Coat screw threads with Loctite.
25. Place rear wall (2) according to the markings
onto bearing housing.
Note: Loctite curing process is completed after
approx. 24 hours only.
26. Install screws and washers and use torque wrench
to tighten to specified tightening torque. Values
( Page 80).
27. Remove sheet strip (3) between heat shield and
turbine wheel rear side.
28. Measuring turbine-side contour clearance:
28.1. Insert core assembly, without compressor
wheel and shaft nut, in turbine housing and
tighten with screws.
28.2. Position dial-gauge anvil on turbine wheel
hub.
28.3. Press down rotor and set dial gauge to zero.
28.4. Press rotor against dial-gauge anvil and
note down measured value.
28.5. Required contour clearance ( Page 510).
29. Following this measurement, remove turbine
housing.
30. Measuring compressor-side contour clearance:
30.1. Push compressor wheel onto shaft. Insert
core assembly, without shaft nut, in
compressor housing and tighten with nuts.
30.2. Position dial-gauge anvil on compressor
wheel hub and set dial gauge to 0.
30.3. Lift compressor wheel as far as it will go and
31. Following this measurement, remove compressor
housing.
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Note: Do not subject shaft to bending stress.
32. Tighten new shaft nut (2) with Tee torque
wrench (1) to specified pretightening torque and
angle of further rotation. Values ( Page 80).
Note: The turbine-side piston rings are properly
seated if heat shield and bearing housing
can easily be rotated after the compressor
wheel has been installed.
33. Secure shaft nut and threaded journal of rotor with
screw locking varnish (arrow).
34. Measuring axial clearance:
34.1. Place dial-gauge anvil under preload on
turbine wheel hub.
note down measured value. Values
( Page 510).
35. Measuring radial clearance:
Note: Radial clearance measurement is
required on turbine side only.
35.1. Place dial gauge stylus in the center of the
seating taper (arrow 1) of the turbine wheel.
35.2. Use dynamometer to pull down turbine
wheel hub at 50 N measurement force
(arrow 2).
35.4. Use dynamometer to pull up turbine wheel
hub at 50 N measurement force (arrow 2).
35.5. Note the reading at the dial gauge. Values
( Page 510).
35.6. Rotate rotor through 90.
35.7. Repeat measurement.
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in groove in rear wall.
37. Place compressor housing (1) onto rear wall,
ensuring that it is not tilted. Observe the markings
made prior to removal.
38. Fit clamping segments (2) and screw on new
nuts (1).
39. Use torque wrench to tighten nuts (1) to specified
tightening torque. Values ( Page 80).
40. Place turbine housing (3) onto bearing housing,
41. Coat thread of screws (1) with assembly paste.
42. Fit clamping segments (2) and insert screws (1).
specified tightening torque. Values ( Page 80).
44. Check rotor shaft for ease of movement.
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5.8.8 Exhaust turbocharger Installation
Special tools
Material
Assembly paste (Ultra Therm) 50547 1
Spare parts
Sealing ring
Sleeve
WARNING
Heavy object.
Risk of crushing!
Exhaust turbocharger Installation
1. Coat studs at threaded end with assembly paste.
2. Install studs and use torque wrench to tighten to specified tightening torque ( Page 80).
3. Fit new sealing rings in exhaust manifold.
4. Position exhaust turbocharger with crane and hook-ended chain sling.
5. Coat thread and nut contact faces with assembly paste.
6. Screw on nuts with sleeves and use torque wrench to tighten crosswise to specified tightening torque
( Page 80).
7. Check-tighten with same tightening torque.
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5.9 Charge-Air Cooling
5.9.1 Intercooler Overview
Intercooler
1 Elbow, left side
2 Vent line
3 End housing, top
4 Intercooler core
5 End housing, bottom
6 Elbow, right side
A Air inlet (from turbocharger)
B Air outlet (to cylinder)
C Coolant inlet
D Coolant outlet
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Intercooler and attachments
1 Intercooler
2 Plug screw
3 Connection housing, bottom
4 Dowel pin
5 Rubber profile
6 Hex bolt
7 Washer
8 Mounting bracket
9 Mounting bracket
10 Screw
11 Washer
12 Screw
13 Screw
14 Mounting bracket
15 Mounting bracket
16 Hex bolt
17 Washer
18 Hex bolt
19 Washer
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5.9.2 Intercooler Removal
Preconditions
WARNING
Heavy object.
Risk of crushing!
Intercooler Removal
1. Remove intercooler and elbow as per overview
2. Attach intercooler to crane with rope and carefully
raise from engine.
3. After removing intercooler, seal all connections on
engine with suitable plugs and covers.
4. Protect intercooler from damage. Cover cooler
meshes.
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5.9.3 Intercooler Cleaning
Work on the intercooler must always be carried out by qualified personnel.
The following sections contain instructions for the cleaning company.
Air-side cleaning
In the event of grease and oil contamination on the intercoolers air side, it is to be cleaned in a closed
cleaning unit. The cleaner must circulate in the opposite direction of the cooling air.
It is essential to avoid damaging the cooler, especially the cooling fins.
To remove deposits, only use a cleaner that does not attack metal surfaces (Operating Instructions ).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Water-side cleaning
It is recommended that the water side is cleaned in a closed cleaning unit with forced flushing and filter.
The water side can also be cleaned in an immersion or ultrasonic bath.
Intercooler Flushing
After cleaning, flush the intercooler with water until the pH values of the clean water and the flushing
water are the same (permissible difference pH value: 1 pH).
Intercooler Drying and preservation
If the cooler is not to be put into operation immediately after cleaning, the cooler is to be dried in a
drying oven for approx. 3 hours at a temperature of 110 to 120 C.
After drying, preserve the cooler with a preservative.
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5.9.4 Intercooler Check
Material
Emery cloth
Spare parts
Intercooler
Elbow
Holder
Plug-in pipe with bell
Plug-in pipe
Drain valve
WARNING
Compressed air.
Risk of injury!
WARNING
Component is hot.
Risk of burning!
WARNING
Hot testing liquid.
Intercooler Check
Item Findings Task
Visually inspect all components for
damage.
Damaged Recondition
Replace
Check all sealing, mating and
contact faces for damage and
unevenness.
Damaged
Uneven
Recondition:
smooth with oilstone or emery
cloth.
Replace
Intercooler Leak check
1. Seal coolant chamber connections on intercooler with suitable sleeves and covers with gaskets and clamps.
2. Connect compressed air line at plug.
3. Preheat test bath to 80 C.
4. Immerse intercooler in test bath.
5. Open compressed air supply and set pressure reducer to 0.5 bar.
6. Pressure-test intercoolers with air in water bath for leaks. Verify that no bubbles rise to the surface.
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7. Replace intercooler if leaks are found.
8. After checking, blow through cooling air ducts with compressed air in vertical direction.
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5.9.5 Intercooler Installation
Material
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
Intercooler Installation
2. Coat O-ring with petroleum jelly and place on
elbow flange.
3. Use crane to place intercooler on engine.
4. Screw screws (5) into mounting brackets (1).
5. Install elbow (3) to intercooler and secure with
screws (2) and nuts (4).
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5.10 Air Intake/Air Supply
5.10.1 Air intake / air supply Overview
1 Intercooler
2 Charge air manifold
3 Connecting elbow
5 Charge air line
6 Air intake
9 Air intake
11 Charge air line
12 Connecting elbow
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5.10.2 Intake housing Overview
Air Intake
1 Connecting piece
2 Rubber sleeve
3 Clamp
4 Clamp
5 Plug
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Air Intake
1 Elbow 2 Clamp
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5.10.3 Intake housing Removal
Preconditions
Intake housing Removal
1. Release clamps and remove air intake as shown in overview drawing ( Page 527).
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5.10.4 Intake housing Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove intake housing ( Page 529).
Intake housing Cleaning
2. Remove cleaner.
3. Thoroughly blow out all components with compressed air.
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5.10.5 Intake housing Check
Spare parts
Elbow
Rubber sleeve
Clamp
Plug
Connector
Clean intake housing ( Page 530).
Intake housing Check
Check connector, elbow and rubber
sleeve for wear, cracks and damage.
Wear
Cracks
Damage
visible
Recondition
Replace
Check clamps, plug for ease of
movement.
Sluggish Recondition
Replace
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5.10.6 Intake housing Installation
Intake housing Installation
1. Remove all seals and plugs.
2. Install air pipework as per overview drawing ( Page 527).
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5.10.7 Intake air system to cylinders, left Overview
3 O-ring
4 Gasket
5 Hex screw
6 Washer
7 Plug
8 Sealing ring
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5.10.8 Air supply system to cylinders, left-hand side Removal
Preconditions
Removing charge-air pipe
1. Remove charge-air pipe as shown in overview drawing, starting with the free end ( Page 533).
2. Remove gaskets and O-rings.
3. After removal, seal all openings with plugs or covers.
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5.10.9 Air supply system to cylinders, left Cleaning
Material
Cleaner (Snow-White 11-0) 40460
Cleaner (Hakupur 312) 30390
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning charge-air manifold
1. Clean left charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out charge-air manifold with compressed air.
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5.10.10 Air supply to cylinders, left side Check
Material
Spare parts
Charge air manifold
Sealing ring
Screws
Plug screw
WARNING
Compressed air.
Risk of injury!
Checking air supply to cylinders, LHS
Item Findings Task
Check charge air manifold for cracks
with red dye penetrant.
Perform leak test on charge air
manifold with air in water bath at a
maximum air pressure of 0.5 bar.
Leaks
at blanking plugs
at charge air manifold
Replace blanking plug.
Replace charge air manifold.
Uneven
Damaged
Recondition: smooth with
oilstone.
Replace
Check threads for ease of
movement.
Sluggish Recut threads.
Replace thread inserts.
Check screws and plugs for damage. Damaged Replace
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5.10.11 Air supply system to cylinders, left-hand side Installation
Material
Engine oil
Spare parts
O-ring
Gasket
CAUTION
CAUTION
Installing air supply system to cylinders, left-hand
side
2. Coat O-ring with grease and fit on charge air
manifold union (2).
3. Coat gaskets with grease and place on sealing
faces (arrows).
4. Install charge-air manifolds (1) as shown in
overview drawing ( Page 533), beginning
with driving end.
5. Insert screws with washer and retainer in charge
air manifold (1) and tighten.
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5.10.12 Air supply system to cylinders, right Overview
3 O-ring
4 Gasket
5 Hex screw
6 Washer
7 Plug
8 Sealing ring
9 Threaded bush
10 Sealing ring
11 Plug
12 Sealing ring
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5.10.13 Air supply system to cylinders, right-hand side Removal
Preconditions
Removing charge air manifold
1. Remove charge-air manifold as per overview drawing starting from the free end . ( Page 538)
3. After removal, seal all openings with suitable plugs or covers.
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5.10.14 Air supply system to cylinders, right Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning the charge-air manifold
1. Clean right charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
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5.10.15 Air supply to cylinders, RHS Check
Material
Spare parts
Charge air manifold
Sealing ring
Screws
Plug screw
WARNING
Compressed air.
Risk of injury!
Checking air supply to cylinders, RHS
Item Findings Task
Leaks
at blanking plugs
Uneven
Damaged
oilstone.
Replace
movement.
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5.10.16 Air supply system to cylinders, right-hand side Installation
Material
Engine oil
Spare parts
O-ring
Gasket
CAUTION
CAUTION
Installing charge air manifold
manifold union (2).
faces (arrows).
with driving end.
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5.10.17 Air pipework from turbocharger to intercooler Overview
Air pipework 12V
1 Connection housing
2 O-ring
3 Spacer sleeve
4 Spacer sleeve
5 Screw
6 Screw
7 Connecting piece
8 O-ring
9 Clamp
10 Plug-in pipe
11 O-ring
12 O-ring
13 Elbow
14 O-ring
15 Screw
16 Washer
17 Nut
18 Connecting piece
19 O-ring
20 Clamp
21 Rubber sleeve
22 Clamp
23 Elbow
24 O-ring
25 Screw
26 Washer
27 Nut
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1 Connecting piece
2 O-ring
3 Clamp
4 Charge-air pipe
5 Rubber sleeve
6 Clamp
7 Retainer
8 Washer
9 Screw
10 Pipe half-clamp
11 Pipe half-clamp
12 Screw
13 Washer
14 Nut
15 Connecting piece
16 O-ring
17 Clamp
18 Charge-air pipe
19 Rubber sleeve
20 Clamp
21 Retainer
22 Washer
23 Screw
24 Pipe half-clamp
25 Pipe half-clamp
26 Screw
27 Washer
28 Nut
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Air pipework 16V
2 O-ring
3 Spacer sleeve
4 Spacer sleeve
5 Screw
6 Screw
7 Connecting piece
8 O-ring
9 Screw
10 Washer
11 Charge-air pipe
12 Rubber sleeve
13 Clamp
14 Plug-in pipe
15 O-ring
16 Elbow
17 O-ring
18 Screw
19 Washer
20 Nut
21 Retainer
22 Washer
23 Washer
24 Screw
25 Pipe half-clamp
26 Pipe half-clamp
27 Screw
28 Washer
29 Nut
30 Connecting piece
31 O-ring
32 Screw
33 Washer
34 Charge-air pipe
35 Rubber sleeve
36 Clamp
37 Connecting piece
38 O-ring
39 Screw
40 Washer
41 Elbow
42 O-ring
43 Screw
44 Washer
45 Nut
46 Retainer
47 Washer
48 Washer
49 Screw
50 Pipe half-clamp
51 Pipe half-clamp
52 Screw
53 Washer
54 Nut
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Intercooler elbow
1 Elbow
2 Plug screw
3 Plug screw
4 Elbow
5 Plug screw
6 O-ring
7 Screw
8 Nut
9 O-ring
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5.10.18 Air pipework from exhaust turbocharger to intercooler Removal
Preconditions
Air pipework from exhaust turbochargers to intercooler Removal
1. Remove air pipework as per overview drawing ( Page 543).
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5.10.19 Air supply from turbocharger to intercooler Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning air pipework
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5.10.20 Air ducts from turbocharger to intercooler Check
Material
Red penetrant dye for surface crack-testing procedure
Spare parts
Charge air line
Connecting housing
Connecting elbow
Connector
Plug-in pipe
Rubber sleeve
Elbow
Spacer sleeve
Screw
Nut
Clamp
Bracket
Clean air ducts from turbocharger to intercooler ( Page 548).
Air ducts from turbocharger to intercooler Check
Using the fluorescent penetrant dye method, check the
connecting housing, elbow, bracket and connection
elbow for cracks.
Crack indication Replace
Check elbow and connection elbow with air under
water, max. air pressure 0.5 bar, for leaks.
Leaking:
at blanking plugs
at elbow
Replace blanking
plug.
Replace elbow.
Check sealing and bolt-on faces for evenness and
damage.
Uneven
Damaged
Recondition:
Smooth with
oilstone.
Replace
Check all threads for ease of movement. Sluggish Recut thread.
Replace thread
inserts.
Check connector, plug-in pipe, charge air line, screws,
clamps and plugs for damage and wear.
Damaged Replace
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5.10.21 Air pipework from turbocharger to intercooler Installation
Material
Spare parts
O-rings
CAUTION
Air pipework from turbocharger to intercooler Installation
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5.11 Exhaust System
5.11.1 Exhaust system Overview
Exhaust system
2 Exhaust system
5 Exhaust pipework connection
6 Exhaust system
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5.11.2 Exhaust pipework after cylinder head Overview
Exhaust pipework 16V (also applicable to 8V / 12V)
1 Exhaust pipe
2 Exhaust pipe
3 Exhaust pipe
4 Exhaust pipe
5 Bellows
6 V-band clamp
7 Insulation
8 Gasket
9 Screw
10 Spacer
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5.11.3 Exhaust pipework after cylinder head Removal
Preconditions
WARNING
Risk of injury!
Exhaust pipework Removal
1. Remove gasket (1).
2. Screw nut onto stud (2) and secure with second
nut.
3. Remove stud (2).
4. Remove screws (1) from band clamps (2).
5. Take off band clamps carefully.
6. Take off insulation.
7. Remove other insulation parts in the same way.
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8. Remove V-band clamps (2) from bellows (1).
9. Remove bellows (1).
10. Remove other bellows in the same way.
11. Remove all screws (1) from exhaust pipes and
take off spacers (2).
12. Remove all exhaust pipes.
13. Seal exhaust ports on cylinder head with suitable
plugs.
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5.11.4 Exhaust pipework after cylinder head Clean
Material
WARNING
Compressed air.
Risk of injury!
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning exhaust pipework after exhaust turbocharger
1. Clean all parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Place components with deposits in a container with decarbonizer. Time for cleaning depends on the layer
thickness of the deposits.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
4. If deposits are stubborn, use synthetic shot-blasting pellets (nominal size 16 to 20) to help cleaning.
5. Remove cleaner.
6. Thoroughly blow all parts clean with compressed air.
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5.11.5 Exhaust pipework after cylinder head Check
Material
Spare parts
Exhaust pipe
Bellows
Hex screw
Gasket
Exhaust pipework after cylinder head Check
Using the surface crack-test
method and red penetrant
dye, check exhaust pipe and
bellows for cracks.
Check hex screws for
damage.
Damaged Replace
Check parts for stress marks,
wear and distortion.
Stress marks
Wear
Distortion
visible
Replace
Check sealing and mating
faces for evenness and
damage.
Uneven
Damaged
Recondition: Smooth with oilstone
Replace
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5.11.6 Exhaust pipework after cylinder head Installation
Special tools
Material
Engine oil 40453 1
Spare parts
Gasket
WARNING
Heavy object.
Risk of crushing!
Exhaust pipework Installation
2. Fit gaskets (1) on all cylinder head exhaust flanges.
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3. Position exhaust pipe starting from engine free
end.
4. Coat screws (1) with engine oil.
5. Insert screws (1) with spacers (2).
6. Tighten screws crosswise.
7. Fit gaskets (arrow) on both flange faces of the
exhaust pipe bellows.
8. Fit two V-band clamps (2) over exhaust pipe
bellows.
9. Position exhaust pipe bellows between exhaust
pipe flanges.
10. Use alignment device (1) to align collar of exhaust
pipe flange and exhaust pipe bellows flush.
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11. Push V-band clamp (2) centrally over flange collar
of exhaust pipe flange and exhaust pipe bellows
and secure with screws.
12. Remove alignment device (1).
13. Push second V-band clamp centrally over flange
collar of exhaust pipe flange and exhaust pipe
bellows and secure with screws.
14. Install further exhaust pipe bellows in the same
way.
15. Fit insulation (2) over exhaust pipe bellows and
secure with band clamps (1).
16. Position band clamps (1) so that screws are
accessible in horizontal position.
17. Tighten screws.
18. Install further insulation parts in the same way.
19. Fit gaskets (1).
20. Insert studs (2) with the small thread ahead into
the flange for the exhaust turbocharger.
21. Tighten studs with locknuts.
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5.11.7 Exhaust pipework after exhaust turbocharger Overview
Exhaust pipework
1 Exhaust elbow 2 Screw 3 Washer
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1 Bellows
2 Sealing ring
3 Clamp
4 Sealing ring
5 Clamp
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5.11.8 Exhaust pipework after exhaust turbocharger Removal
Preconditions
Exhaust pipework after exhaust turbocharger Removal
1. Remove exhaust pipework as per overview drawing ( Page 560).
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5.11.9 Exhaust pipework after turbocharger Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove exhaust pipework after exhaust turbocharger ( Page 562).
Exhaust pipework after turbocharger Cleaning
2. Place parts displaying soot deposits in a bath containing carbon-deposit remover. Dwell time depends on
thickness of deposits.
3. After cleaning with carbon-deposit remover, rinse components in water until no further residues are washed off.
5. Remove cleaner.
6. Blow out exhaust lines thoroughly.
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5.11.10 Exhaust pipework after exhaust turbocharger Check
Material
Spare parts
Exhaust elbow
Washer
Bellows
Clamp
Checking exhaust pipework after exhaust turbocharger
Item Findings Task
Check exhaust elbow with red dye
penetrant for cracks.
Check parts for stress marks, wear
and deformation.
Stress marks
Wear
Deformation
visible
Replace
flatness and damage.
Uneven
Damaged
Corrective work: Smoothen
with oilstone
Replace
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5.11.11 Exhaust pipework after exhaust turbocharger Installation
Material
Assembly paste (Ultra-Therm MTU) 50547 1
Spare parts
Sealing ring
Exhaust pipework after exhaust turbocharger Installation
1. Prior to assembly, coat screw threads with assembly paste.
2. Install exhaust elbow and bellows as per overview drawing ( Page 560).
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5.11.12 Exhaust pipework after engine Overview
Exhaust pipe bellows
1 Bellows
2 Sealing ring
3 Clamp
4 Insulation
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Companion flange
1 Flange
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5.11.13 Exhaust pipework after engine Removal
Exhaust pipework after engine Removal
1. Remove exhaust pipework according to overview drawing ( Page 566).
2. After removal, seal all openings.
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5.11.14 Exhaust pipework after engine Cleaning
Material
Cleaner
Decarbonizer
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove exhaust pipework after engine ( Page 568).
Exhaust pipework after engine Cleaning
5. Remove cleaner.
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5.11.15 Exhaust pipework after engine Check
Spare parts
Flange
Clamp
Insulation
Clean exhaust pipework after engine ( Page 569).
IExhaust pipework after engine Check
Check exhaust pipe bellows and flange for wear
and distortion.
Traces of wear
Wear
Deformation
visible
Replace
Check insulation for damage Damaged Replace
Check clamps for ease of movement. Sluggish Recondition
Replace
Check sealing and mating faces for evenness and
damage.
Uneven
Damaged
Recondition: smooth
with oilstone
Replace
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5.11.16 Exhaust pipework after engine Installation
Material
Spare parts
Sealing ring
Check exhaust pipework after engine ( Page 570).
Exhaust pipework after engine Installation
2. Install exhaust pipe bellows as shown in overview drawing ( Page 566).
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5.12 Starting Equipment
5.12.1 Electric starter Overview
1 Starter (for 12V/16V on left
engine side)
2 Starter, right engine side
3 Hex screw / Allen screw
4 Gear ring
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1 Terminal 45
2 Terminal 30
3 Terminal 50
4 Housing for engagement lever
5 Engagement relay
6 Commutator cover
7 Terminal 31
8 Starter housing
9 Driver housing
10 Terminal 30
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5.12.2 Starter Removal
Preconditions
DANGER
Electrical voltage.
Risk of serious injury - danger to life!
Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!
WARNING
Heavy object.
Risk of crushing!
Disconnecting and removing starter
1. Before disconnecting, mark all cables with writable
adhesive tape for identification.
Connection terminal 30 = positive cable
Connection terminal 50 = control cable
Connection terminal 31 = ground cable
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Depending on the version, remove hex screws or
Allen screws (1) from starter.
5. Remove starter.
6. Protect starter from damage.
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5.12.3 Starter Disassembly
Starter Disassembly
Entrust starter overhaul to an authorized and specialized company only.
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5.12.4 Starter Cleaning
WARNING
Compressed air.
Risk of injury!
Starter Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against humidity.
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5.12.5 Starter Check
Spare parts
Starter
WARNING
Compressed air.
Risk of injury!
Starter Check
Item Findings Task
Check tooth flanks of drive gear for
wear, indentations and chipping.
Wear
Indentations
Chipping
visible
Recondition
Replace
Check nuts and studs for condition
and check threads for ease of
movement.
Sluggish Replace
Check mating face on end housing
for wear.
Wear traces are found. Recondition: smooth with oilstone
or emery cloth.
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5.12.6 Starter Installation
Material
Long-life grease (Longtherm 2 Plus) 40336 1
DANGER
Electrical voltage.
WARNING
Heavy object.
Risk of crushing!
Installing starter
1. Coat starter pinion with long-life grease.
2. Attach starter to crane.
3. Insert starter into opening on end housing.
4. Align bores for securing screws on starter with
those on flange.
5. Secure starter to flange with screws (1).
Connecting starter cables
1. Connect cables as per marking on starter ( Page 574).
(1) = terminal 45 = internal control cable (already connected)
(2) = terminal 30 = positive cable
(3) = terminal 50 = control cable
(4) = terminal 31 = ground cable
2. Check operation of starter.
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5.12.7 Flame starting system Overview
Attachments for flame starting system
1 Flange
2 Insulating washer
3 Nut
4 Fuel nipple
5 Sealing element
6 Protective shroud
7 Screw
8 Screw
9 Fuel line
10 T-piece
11 Fuel line
12 Fuel line
13 T-piece
14 Fuel line
15 Fuel line
16 Fuel line
17 Bracket
18 Pipe half-clamp
19 Grommet
20 Screw
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1 Bracket
2 Bracket
3 Screw
4 Screw
5 Screw
6 Washer
7 Pressure regulator
8 Screw
9 Spacer bush
10 Pipe half-clamp
11 Screw
12 Union
13 Sealing ring
14 Bracket
15 Screw
16 Screw
17 T-piece
18 Fuel line
19 Adapter
20 Sealing ring
21 Fuel line
22 Adapter
23 Sealing ring
24 Adapter
25 Sealing ring
26 Fuel line
27 Adapter
28 Sealing ring
29 Pipe half-clamp
30 Grommet
31 Screw
32 Fuel line
33 Bracket
34 Screw
35 Washer
36 Pipe half-clamp
37 Pipe half-clamp
38 Grommet
39 Screw
40 Fuel line
41 Bracket
42 Screw
43 Pipe half-clamp
44 Grommet
45 Screw
46 Fuel line
47 Bracket
48 Pipe half-clamp
49 Grommet
50 Screw
51 Fuel line
52 Non-return valve
53 Fuel line
54 Non-return valve
55 Bracket
56 Pipe half-clamp
57 Grommet
58 Screw
59 Fuel line
60 Fuel line
61 Blanking cone
62 Nut
63 Fuel line
64 Non-return valve
65 Fuel line
66 Grommet
67 Grommet
68 Pipe half-clamp
69 Pipe half-clamp
70 Pipe half-clamp
71 Pipe half-clamp
72 Washer
73 Spacer pipe
74 Screw
75 Bracket
76 Screw
77 Grommet
78 Pipe half-clamp
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5.12.8 Flame starting system Removal
WARNING
Do not smoke.
Removing flame torches
1. Remove screws (arrowed) from protective cover.
2. Hold sealing element (2) securely and carefully
remove protective cover.
3. Removing fuel lines (1).
5. Disconnect control cable at connections (arrowed).
6. Remove sealing element (2).
7. Release flange (4).
8. Remove flame torch (3).
9. Remove insulating washer (5).
Removing fuel lines and externally mounted components
1. Before removing the lines, take photos or mark lines and externally mounted components.
2. Remove lines as shown in the overview drawing ( Page 579).
3. After removal, seal all connections with plugs.
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5.12.9 Flame starting system Cleaning
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove flame starting system ( Page 581).
Flame starting system Cleaning
1. Clean all components with cleaning agent.
3. Blow out all components thoroughly with compressed air.
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5.12.10 Flame starting system Check
Spare parts
Flange
Insulating washer
Nut
Fuel nipple
Sealing element
Protective shroud
Fuel line
T-piece
Bracket
Bracket
Pressure regulator
Spacer bush
Union
WARNING
Risk of injury!
Clean flame starting system ( Page 582).
Flame starting system Check
Visually check all fuel lines and attachments for
damage.
Damaged Recondition
Replace
Check fuel lines with air bottom water for leaks.
Maintain a coolant temperature of min. = 30 C or
max. = 40 C at a test pressure of 0.5 bar.
Leaking Replace
Check all threads for damage and ease of
movement.
Damaged
Thread sluggish.
Recondition:
Recut thread.
Replace
Check sealing and screw-on surfaces for damage. Damaged Recondition:
Smooth with
oilstone.
Replace
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5.12.11 Flame starting system Installation
Spare parts
Sealing ring
Grommet
WARNING
Do not smoke.
CAUTION
Check flame starting system ( Page 583).
Install flame starting system
2. Blow fuel lines clear with compressed air.
3. Install fuel lines without tension as shown in the overview drawing ( Page 579) or as per photos/marks
made during removal.
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5.13 Lube Oil System, Lube Oil Circuit
5.13.1 Lube-oil pump with drive Overview
1 Oil pump
2 Screw
3 Washer
4 Screw
5 Pressure reducing valve
6 Banjo screw
7 Sealing ring
8 Oil line
9 Retainer
10 Pipe half-clamp
11 Grommet
12 Screw
13 Spacer sleeve
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5.13.2 Lube-oil pump with drive Removal
Special tools
WARNING
Heavy object.
Risk of crushing!
Removing oil pump with safety valve
Note: The illustration does not show engine in
installation position.
1. Unscrew all screws (1) on the oil pump (2).
2. Attach support bracket to oil pump and with rope,
slightly tensioned, to crane.
3. Remove oil pump from equipment carrier and
place aside.
Removing oil line and pressure reducing valve
1. Remove oil line from equipment carrier as per overview drawing ( Page 585).
2. Remove pressure reducing valve from equipment carrier.
4. Seal connections with suitable plug.
5. Protect oil line from damage.
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5.13.3 Lube-oil pump with drive Disassembly
Lube-oil pump Disassembly
1. Do not disassemble lube oil pump.
2. Contact Service.
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5.13.4 Lube oil pump with drive Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning oil line
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5.13.5 Lube-oil pump with drive Check
Material
Spare parts
Oil pump
Pressure reduction valve
Oil line
Banjo screw
Screw
Pipe half-clamp
WARNING
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Lube-oil pump with drive Check
Item Findings Task
Visually inspect outside of lube-oil
pump for damage and defects.
Damaged Have lube-oil pump operation
checked and repaired at
manufacturer.
Visually inspect oil line for damage. Damaged Corrective work
Replace
Check sealing faces for irregularities. Uneven Corrective work and check for
evenness with ink-check plate.
Replace
Damaged
Sluggish
Replace
Check drive gear with dye penetrant
for cracks.
Check tooth flanks of drive gear
for stress marks, indentations and
chipping.
Stress marks
Indentations
Chipping
visible
Corrective work
Replace lube-oil pump
Check breather valve for opening
pressure of 15 bar. Test medium:
Engine oil SAE 30 medium
temperature: from 90 C to 100 C.
Opening pressure not reached or
exceeded.
Replace
Disassembly of the pressure
reduction valve is not planned;
check for damage by visual
inspection only.
Damaged Replace
Check pressure reduction valve
opening pressure. Operation: The
valve limits the oil flow so that a
constant pressure of 5.5 +1 bar is
maintained at the last crankshaft
bearing. Medium temperature: from
90 C to 100 C, design pressure at
n/min 1.5 bar at n/max 7 bar of oil
pump.
Opening pressure not reached, or
exceeded.
Replace
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5.13.6 Lube oil pump with drive Installation
Special tools
Material
Engine oil
Spare parts
Sealing ring
Grommet
O-ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Heavy object.
Risk of crushing!
WARNING
Compressed air.
Risk of injury!
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Installing lube oil pump on equipment carrier
1. Degrease sealing face on equipment carrier
and lube-oil pump.
2. Apply surface sealant to sealing surface on
equipment carrier.
3. Attach oil pump with carrying bracket to crane.
4. Insert oil pump into equipment carrier, making
sure gears engage correctly.
5. Screw in screws (1) and (2) for oil pump and use
torque wrench to tighten diagonally to specified
tightening torque .
Installing pressure reducing valve
1. Coat O-ring with grease and insert in groove of
pressure reducing valve (arrow).
2. Insert pressure reducing valve (1) in equipment
carrier and tighten to specified torque using a
torque wrench .
Pressure reducing
valve
Tightening torque Engine oil 60 Nm +20 Nm
Installing oil line
1. Prior to installation, remove all blanking plugs.
2. Blow out oil line with compressed air.
3. Install oil line loosely using attaching parts as per overview drawing ( Page 585).
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5.13.7 Oil filter Overview
Oil filter housing
1 Oil filter housing
2 O-ring
3 O-ring
4 Hex screw
5 Washer
6 Bracket
7 O-ring
8 O-ring
9 Hex screw
10 Hex screw
11 Oil Filter
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Differential pressure monitor
1 Sealing ring
2 Washer
3 Hex nut
4 Connector
5 Pipe
6 Adapter
7 Differential pressure monitor
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5.13.8 Oil filter with oil filter housing Removal
Special tools
Removing oil filter
1. Remove oil filter with filter wrench.
2. Drain oil from oil filter into a suitable container.
Removing oil filter housing
1. Remove oil filter housing according to overview
2. Seal connections (arrows) with plugs.
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5.13.9 Oil filter housing Disassembly
Remove oil filter housing ( Page 595).
Oil filter housing Disassembly
1. Remove threaded fittings (3) from oil filter housing
(2).
2. Unscrew all plugs.
3. Remove O-rings (5).
4. Remove plug (3) and remove valve.
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5.13.10 Oil filter housing Clean
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning oil filter housing
2. Blow out/off all parts with compressed air.
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5.13.11 Oil filter housing Check
Special tools
Test bath
Spare parts
Oil filter housing
Bracket
Connector
Pipe
Adapter
Nut
Washer
WARNING
Hot testing liquid.
Clean oil filter housing ( Page 597).
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Oil filter housing Check
sliding surfaces for wear, scoring
and indentations.
Wear
Scores
Indentations
visible.
Recondition: smooth with oilstone or
emery cloth.
Replace
bores.
Damaged Recondition: recut thread.
Replace
Pressure-test oil filter housing
with air in water bath for leaks.
Install filter inserts before carrying
out leak check. Test temperature:
min. 30 C, max. 40 C, if oil filter
housing has to be held in hands.
Test pressure: 0.5 bar.
Leaking Replace plugs.
Replace valve.
Replace oil filter housing.
Check differential pressure
monitor, bracket and line for
mechanical damage.
Damaged Replace
Check spring of pressure limiting
valve for wear.
Wear Replace
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5.13.12 Oil filter housing Assembly
Material
Spare parts
O-rings
Plugs
CAUTION
Check oil filter housing ( Page 598).
Oil filter housing Assembly
1. Screw threaded fittings (3) into oil filter housing (2).
2. Coat O-rings for plugs (4) with petroleum jelly.
3. Screw in plugs.
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4. Coat O-rings for grooves with petroleum jelly.
5. Insert valve with spring in bore (3).
6. Insert plug (3).
7. Insert O-rings in grooves.
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5.13.13 Oil filter with oil filter housing Installation
Material
Engine oil
Spare parts
O-rings
CAUTION
Assemble oil filter housing ( Page 600)
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Installing oil filter housing
2. Install oil filter housing as shown in overview
4. Insert O-ring in groove (1) of oil filter housing (2).
Installing oil filter
1. Coat sealing ring of oil filter with oil.
2. Install oil filter and tighten by hand.
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5.13.14 Centrifugal oil filter Overview
Centrifugal oil filter with attachments
1 Centrifugal oil filter
2 Hex screw
3 Washer
4 Sealing ring
5 Sealing ring
6 Adapter
7 Sealing ring
8 Oil line
9 Hex nut
10 Screw
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Centrifugal oil filter with flange
2 Flange
3 O-ring
4 Screw
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Centrifugal oil filter assembly
1 Housing
2 Valve
3 Sealing ring
4 Valve piston
5 Plug
6 Compression spring
7 O-ring
8 Cover
9 Cover
10 Cover screw
11 Screw
12 Pin
13 O-ring
14 Drain screw
15 Clamp
16 Rotor unit
17 Nozzle
18 Substructure with bearing
19 Standpipe
20 Snap ring
21 O-ring
22 Pin
23 Knurled nut
24 Insertion sleeve
25 Reinforcing plate
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5.13.15 Centrifugal oil filter Removal
Preconditions
Centrifugal oil filter Removal
1. Remove centrifugal oil filter as shown in overview drawing ( Page 604).
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5.13.16 Centrifugal oil filter Disassembly
Disassembling centrifugal oil filter
1. Release nut with toggle (2) and remove V-band
clamp (1).
2. Release screw from cover (1).
3. Remove cover (1) from housing (2).
4. Drain residual oil from centrifugal oil filter into a
suitable container.
5. Carefully remove rotor unit (1) from
shaft/housing (3). Avoid damaging bearing
or shaft.
7. Remove valve piston, plug and pressure spring as
shown in the overview drawing ( Page 604).
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Note: Take care not to interchange rotors
belonging to different centrifugal filters
because rotor hood and substructure are
aligned to one another during manufacture.
8. Release knurled nut (1) and remove rotor hood (3)
with cover plate (2) from rotor substructure (4).
9. Remove paper element from rotor hood (3).
10. Remove pipe (1) from rotor (2).
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5.13.17 Centrifugal oil filter Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning the rotor unit
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5.13.18 Centrifugal oil filter Check
Material
Spare parts
Housing
Rotor
Nozzle
Pipe
Screw
Compression spring
Valve plunger
Plug
Centrifugal oil filter Check
Item Findings Task
Check all sealing, mating and sliding
surfaces for wear, scoring and
indentations.
Wear
Scores
Indentations
visible.
Replace
Using red penetrant dye, check the
housing and substructure for cracks.
Cracks indicated Replace rotor unit.
bores.
Damaged Recondition: recut threads.
Replace
Check journals on rotor and bearing
running surfaces on shaft for wear.
Wear visible Recondition: smooth with
Replace
Check valve piston and spring
( Page 604) for wear traces.
Wear visible Recondition
Replace
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5.13.19 Centrifugal oil filter - Bearing clearance check
Special tools
Retainer 0015890321/00 1
Spare parts
Rotor
Clean centrifugal oil filter ( Page 610).
Checking bearing clearance of rotor
1. Arrange dial gauge with dial gauge stylus opposite rotor.
2. Align dial gauge stylus to upper rotor edge, set dial gauge to zero.
3. Rotate rotor in 4 steps of 90. Read dial gauge and record reading. Max. measured value = bearing clearance,
specified value 0.08 mm.
4. With bearing clearance > 0.25 mm, replace complete rotor unit.
5. Align dial gauge stylus to lower rotor edge, set dial gauge to zero.
8. Measure bearing diameter:
Diameter at upper bearing running surface of shaft: 14.98 mm
Diameter at lower bearing running surface of shaft: 21.63 mm
Inner diameter of upper bearing: 15.06 mm
Inner diameter of lower bearing: 21.69 mm
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5.13.20 Centrifugal oil filter Assembly
Special tools
Material
Engine oil
Spare parts
Paper element
O-ring
Sealing ring
WARNING
Heavy object.
Risk of crushing!
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Assembling rotor unit
1. Fit pipe (1) on rotor (2).
2. Insert gaiter (2) in cover (1).
3. Coat O-ring (arrowed) with grease and insert
in groove on cover.
4. Fit cover (1) with new paper element (2) on rotor.
5. Turn cover (1) so that chase (3) and pin (4) are
flush with one another.
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6. Install cover plate (2) and tighten knurled nut (1)
by hand.
7. Coat shaft with engine oil.
8. Carefully insert rotor unit in housing (2).
9. Check that rotor rotates freely.
10. Coat O-ring with grease and insert in groove (1)
on housing (2).
11. Place cover (1) on housing (2) and use torque
wrench to tighten cover screw to specified
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12. Install V-band clamp (1) and use torque wrench
to tighten nut (2) to specified tightening torque
( Page 80).
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5.13.21 Centrifugal oil filter Installation
Material
Spare parts
O-ring
CAUTION
CAUTION
Centrifugal oil filter Installation
2. Coat O-ring with grease and insert.
3. Install centrifugal oil filter as shown in overview drawing ( Page 604).
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5.13.22 Oil heat exchanger Overview
1 Insert
2 O-ring
3 Housing
4 O-ring
5 Washer
6 Nut
7 Screw
8 Screw
9 Plug-in pipe
10 O-ring
11 Retainer
12 Nut
13 O-ring
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5.13.23 Oil heat exchanger Removal
Preconditions
Special tools
Eyebolt B80090843 2
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Avoid contact with skin.
Do not inhale oil vapor.
WARNING
Heavy object.
Risk of crushing!
Removing oil heat exchanger
1. Remove screws (3) from oil heat exchanger
housing.
2. Remove nuts (1).
3. Screw eyebolts (2) into the left and right oil heat
exchanger housing.
4. Using crane and rope, remove oil heat exchanger
housing from coolant distribution housing.
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5. Remove sealing washers (1).
6. Carefully remove oil heat exchanger (arrowed)
vertically upwards from coolant distribution
housing fit.
7. Seal all openings and connections with suitable
plugs.
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5.13.24 Oil heat exchanger Cleaning
Material
Cleaning agent
CAUTION
CAUTION
Cleaning oil heat exchanger housing and plug-in pipe
1. Clean oil heat exchanger housing and plug-in pipe with cleaner.
Cleaning oil heat exchanger on water and oil side.
Note: If swarf has got into the engine oil system, e.g. as a result of piston scuffing or bearing damage, replace oil
heat exchanger.
Cleaning water side
1. Examine the degree of contamination.
2. In event of visible encrustation as a result of hardness structure, contamination and oil deposits, clean with
suitable cleaners, e.g. Porodox (from Henkel) or Porozink (from Parobe-Chemie, Basel). Always follow
manufacturers instructions.
3. After cleaning, flush the oil heat exchanger with water until pH values of clean water and flushing liquid are
approximately the same (difference 1 pH).
4. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve coolant side.
Cleaning oil side
1. Connect oil heat exchanger (oil side) to a closed flushing system with a filter system of 0.05 mm mesh size.
2. Clean oil heat exchanger with suitable cleaner, e.g. buffered alkaline agents such as 3 to 5% solution
of Henkel P3 FD.
3. Ensure flow direction of cleaner is against normal direction of oil flow during operation.
4. After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are
roughly equal (permissible difference 1pH).
5. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve oil side.
Drying and preserving oil heat exchanger
1. Dry oil heat exchanger in oven at 110 C to 120 C for approx. 3 hours.
2. Spray preservative (Branorol 32/10 from Brangs & Heinrich) into the oil heat exchanger. A dosage of max.
2 ml Branorol 32/10 per litter of cooling volume must be observed. The preservative vaporizes and forms a
protective film on all interior surfaces.
3. After preservation, seal all openings airtight with suitable plugs.
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5.13.25 Oil heat exchanger Check
Material
Red dye penetrant for surface crack-testing procedure
Spare parts
Oil heat exchanger housing
Heat exchanger core
Retainer
Plug-in pipe
WARNING
Compressed air.
Risk of injury!
WARNING
Hot testing liquid.
WARNING
Component is hot.
Risk of burning!
CAUTION
Oil heat exchanger check
damage.
Replace
unevenness.
Damaged
Uneven
Corrective work:
Smooth with oilstone or crocus
cloth.
Replace
Check thread for easy movement. Sluggish Recut
Replace
Check oil heat exchanger housing
for cracks with red dye penetrant.
Cracks indicated Replace
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Heat exchanger core leak check
1. Seal oil chamber connections of heat exchanger
core (3) with suitable sleeves, blanking plugs,
plugs (2) and clamps.
2. Connect pressure line (1) at plug (2).
4. Immerse heat exchanger core (3) in test bath.
5. Open compressed air supply and set pressure
reducer (1) to 0.5 bar.
6. Pressuretest heat exchanger core (3) for leaks
with air in water bath; no bubbles should emerge.
7. Replace heat exchanger core (3) if leaky.
8. Remove compressed-air line (1), sleeves and
plug (2).
9. Blow out cooling fins of heat exchanger core (3)
with compressed air in vertical direction.
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5.13.26 Oil heat exchanger Installation
Special tools
Eyebolt B80090843 2
Material
Engine oil (MZK engine oil HD 10W) 40453 1
Spare parts
O-ring
O-ring
WARNING
Heavy object.
Risk of crushing!
CAUTION
Installing oil cooler
1. Remove all plugs from coolant distribution housing.
2. Clean oil chambers and oil galleries (arrowed).
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3. Coat O-rings on heat exchanger core with grease.
4. Place heat exchanger core in coolant distribution
housing with label IN towards the driving end.
5. Place disks (1) on the threads of the heat
exchanger cores.
6. Coat O-ring (3) with grease and insert into groove
on the elbow (2).
7. Loosen screws on elbow (2).
on the oil heat exchanger housing (2).
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9. Coat O-rings on plug-in pipe (2) with grease
before installation.
10. Mount plug-in pipe (2) with retainer (3) on oil heat
exchanger housing (1).
11. Screw eyebolts into the oil heat exchanger
housing (1).
12. Using crane and rope, position oil heat exchanger
housing (1) on coolant distribution housing.
13. Screw oil heat exchanger housing (1) into place
with the screws on the coolant distribution housing.
14. Remove eyebolts (2) from both oil heat exchanger
housings.
16. Screw on nuts (1) and tighten with torque wrench
to the specified tightening torque ( Page 80).
17. Tighten the screws (2) on the elbow (1) of the
coolant distribution housing.
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5.13.27 Oil system in crankcase Overview
Oil system
1 Delivery valve
2 O-ring
3 O-ring
4 Circlip
5 Washer
6 O-ring
7 O-ring
8 Retainer
9 Retainer
10 Pipe
11 Pipe
12 Oil spray nozzle
13 Screw
14 Circlip
15 Delivery valve
16 O-ring
17 O-ring
18 Washer
19 O-ring
20 O-ring
21 Retainer
22 Retainer
23 Pipe
24 Pipe
25 Oil spray nozzle
26 Screw
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1 Delivery valve
2 O-ring
3 Washer
4 O-ring
5 Pipe
6 Retainer
7 Retainer
8 Retainer
9 Oil spray nozzle
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5.13.28 Oil system in crankcase Removal
Preconditions
Special tools
WARNING
Risk of injury!
Removing bracket for oil spray nozzle
1. Install barring device at crankshaft ( Page 245).
2. Turn crankshaft with barring device until oil spray
nozzle (1) to be removed is accessible.
3. Remove screws (arrows).
4. Remove oil spray nozzle (1) from retainer (2).
5. Mark oil spray nozzle (1) with a pen according to
cylinder side and cylinder number.
6. Protect oil spray nozzle (1) against damage.
Removing oil pipe connection
1. Remove screw (arrows).
2. Remove holder (2) from oil pipe fit (3).
3. Remove oil pipe (1) from retainer (2).
4. Remove all other oil spray nozzles in same
manner.
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Removing washer (sealing fit)
1. Remove washer (2) from crankcase (1).
2. Remove O-rings.
3. Protect washer (2) against damage.
Removing delivery valve
1. Remove pressure valve as per overview drawing
( Page 627).
2. Unscrew plug screws.
3. Remove snap ring (1) from housing.
4. Remove delivery valve (3) from housing.
5. Remove O-rings (2) and (4)
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5.13.29 Oil pipework in crankcase Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning oil spray nozzles and oil pipes
2. Remove cleaner.
3. Blow oil pipes, retainers and oil spray nozzle dry with compressed air.
Cleaning washer (sealing fit)
2. Remove cleaner.
3. Then blow washer dry (sealing fit) with compressed air.
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5.13.30 Oil pipework in crankcase Check
Special tools
Material
Spare parts
Oil spray nozzle
Pipe
Retainer
Washer (sealing fit)
Delivery valve
DANGER
Component to be tested is under pressure.
Risk of explosion!
Observe test specification.
WARNING
Risk of injury!
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Oil pipework in crankcase Check
Item Findings Task
Check oil spray nozzles with dye
Check oil bore of oil spray nozzles
for obstruction and ensure it is
particularly clean.
Contamination visible. Corrective work: Clean
Replace
Check oil spray nozzle with testing
device for deformation.
Deformation of oil spray nozzle. Replace
Test oil pipes for leaks with air in
water bath as necessary. Maintain a
water temperature of min. = 30 C
or max. = 40 C and a test pressure
of 0.5 bar.
Leaking Replace
movement.
Replace
Check mating and sealing faces of
oil spray nozzle.
Damaged
Stress marks
visible
Replace
Check washer (sealing fit) for wear,
cracks and damage.
Stress marks
Cracks
Damage
visible
Replace
Check bore in crankcase for wear. Visible signs of wear. Smooth with emery cloth.
Do not disassemble delivery valve!
Visually inspect delivery valve for
damage.
Damaged Replace
Check delivery valve for read
opening pressure 0.25 bar.
Fallen short of or exceeded Replace delivery valve.
Check sealing face of delivery valve
for evenness.
Uneven Corrective work: Smooth with
oilstone.
Replace
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5.13.31 Oil system in crankcase Installation
Special tools
Material
Engine oil
Spare parts
O-rings
Snap ring
WARNING
Compressed air.
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Installing oil spray nozzle bracket and oil pipes
2. Install bracket (1) so that dimension "a" points
towards crankcase.
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3. Coat O-rings with grease and insert into grooves in
oil pipes (1) and (3).
4. Fit oil pipes (1) and (3) in retainer (2) and secure
with screws (arrow) on crankcase.
5. Install oil spray nozzle (1) on retainer and align
with alignment device (3).
specified tightening torque.
7. After installing, bar engine and ensure there is
clearance between oil spray nozzle and piston.
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Installing washer (sealing fit)
1. Coat O-rings with grease and insert into grooves
(arrows) of washer.
2. Align oil pipe so that inner O-ring is not damaged.
3. Press-fit washer (2) manually in crankcase (3).
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Installing delivery valve
1. Coat O-ring (arrow) with grease and insert in
groove (arrow).
2. Coat O-ring (arrow) with grease and insert into
groove on delivery valve.
3. Insert delivery valve (3) into bore of housing
as far as it will go.
4. Secure delivery valve with snap ring (1) and
install plug screw.
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5.13.32 Turbocharger oil supply Overview
ETC oil supply
1 Oil line
2 O-ring
3 Screw
4 O-ring
5 Threaded adapter
6 O-ring
7 Retainer
8 Washer
9 Screw
10 Washer
11 Pipe half-clamp
12 Pipe half-clamp
13 Grommet
14 Washer
15 Screw
16 Retainer
17 Washer
18 Screw
19 Washer
20 Pipe half-clamp
21 Pipe half-clamp
22 Grommet
23 Washer
24 Screw
25 Oil line
26 O-ring
27 Screw
28 O-ring
29 Threaded adapter
30 O-ring
31 Retainer
32 Washer
33 Screw
34 Washer
35 Pipe half-clamp
36 Pipe half-clamp
37 Grommet
38 Washer
39 Screw
40 Retainer
41 Washer
42 Screw
43 Washer
44 Pipe half-clamp
45 Pipe half-clamp
46 Grommet
47 Washer
48 Screw
49 Oil line
50 Oil line
51 Gasket
52 Screw
53 Gasket
54 Nut
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5.13.33 Turbocharger oil supply Removal
Preconditions
Turbocharger oil supply Removal
1. Remove oil line, unions and fixtures as per overview drawing ( Page 638).
2. Remove all sealing elements.
4. Protect oil lines from damage.
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5.13.34 Turbocharger oil supply Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Turbocharger oil supply Cleaning
2. Remove cleaner.
3. Blow turbocharger oil supply pipework dry with compressed air.
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5.13.35 Turbocharger oil supply Check
Spare parts
Pipe
Flange
Adapter
Strap
WARNING
Compressed air.
Risk of injury!
WARNING
Risk of injury!
Turbocharger oil supply Check
Item Findings Task
Visually inspect oil return line for
damage.
Damaged Replace
Pressure-test oil return line with air
in water bath for leaks. Maintain a
of 0.5 bar.
Leaking Replace
Check connection parts and
securing elements on oil return lines
for damage.
Damaged Replace
Check sealing and bolt-on faces. Damaged Corrective work: Smooth with
Replace
movement.
Replace
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5.13.36 Turbocharger oil supply Installation
Material
Engine oil
Spare parts
O-rings
Grommet
Sealing ring
Pipe half-clamp
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
Turbocharger oil supply Installation
2. Coat O-rings with grease and insert.
3. Insert sealing rings.
4. Install turbocharger oil supply ( Page 638).
5. After starting the engine, visually inspect oil lines for leaks.
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5.14 Coolant System
5.14.1 Coolant system Overview
Coolant circuit with internal thermostat
1 Intercooler
2 Connection, engine coolant
vent line (low-temperature
coolant circuit)
vent line (high-temperature
coolant circuit)
4 Engine coolant expansion tank
5 Engine coolant heat exchanger
(low-temperature coolant circuit)
6 Fan cooler
7 Thermostat (cooler fan in charge
air coolant system)
(high-temperature coolant circuit)
9 Thermostat for cooler fan
outlet to cooler (low-temperature
coolant circuit)
11 Connection, engine coolant inlet
from cooler (low-temperature
coolant circuit)
expansion line (low-temperature
coolant circuit)
outlet to cooler (high-temperature
coolant circuit)
from cooler (high-temperature
coolant circuit)
expansion line (high-temperature
coolant circuit)
16 Engine coolant thermostat
17 Lube oil heat exchanger
18 Engine coolant pump
19 Crankcase
20 Coolant pump for charge air
cooling circuit
22 Thermostat, engine coolant
preheating unit
23 Circulation pump for preheating unit
24 Coolant preheating unit
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Coolant circuit with external thermostat
1 Intercooler
coolant circuit)
coolant circuit)
6 Fan cooler
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
17 Crankcase
preheating unit
cooling circuit
air coolant system)
24 Dummy thermostat, open, blocked
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5.14.2 Engine coolant pump Overview
2 O-ring
3 Screw
4 Screw
5 Screw
6 Nut
7 Washer
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1 Water pump shaft
2 Impeller
3 Bearing housing
4 Seal carrier
5 Volute
6 Spacer sleeve
7 Gear
8 Angular-contact ball bearing
9 Cylindrical roller bearing
10 Snap ring
11 Shaft seal
12 Rotary seal
13 O-ring
14 Screw
15 Washer
16 O-ring
17 Screw
18 Washer
19 Sealing ring
20 Plug screw
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5.14.3 Engine coolant pump Removal
Preconditions
Special tools
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Engine coolant pump Removal
1. Attach engine coolant pump with lifting gear and support bracket to crane using a slightly tensioned rope.
2. remove screws for engine coolant pump as per overview drawing ( Page 645).
3. Use crowbar to separate engine coolant pump from front cover and remove.
4. Remove O-ring.
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5.14.4 Engine coolant pump Disassembly
Special tools
Hydraulic spindle F6781539 1
Puller tool for impeller F6780562 1
Puller tool for gear F6780561 1
Holding fixture F6781573 1
Carrier for several mandrels F30275611 1
Impact extractor for shaft seal F30450991 1
WARNING
Heavy object.
Risk of crushing!
WARNING
WARNING
Risk of injury!
Engine coolant pump Disassembly
1. Mark installation position of bearing housing (1)
and volute (3) in relation to one another.
2. Remove all bolts (2).
3. Use crowbar to separate volute (3) from bearing
housing (1) and remove it.
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4. Place engine coolant pump in (2) retaining
device (1).
5. Use hydraulic spindle (1) and puller tool for impeller
(2) to remove impeller (3) from pump shaft.
6. Holding the gear firmly in the retaining device
throughout.
7. Take off impeller (3) from engine coolant pump.
8. Remove bellows joint seal from pump shaft.
9. Take engine coolant pump out of retaining device.
10. Place bearing housing (3) with pump shaft in vise
with aluminum jaws.
11. Use hydraulic spindle (1) and puller tool (2) to
remove gear from water pump shaft.
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12. Use snap ring pliers (4) to remove snap ring (2)
for cylindrical roller bearing (3) from bearing
housing (1).
13. Remove all screws (1) using box wrench (2).
14. Take bearing housing (2) out of vise and take
off seal carrier (1).
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15. Use hydraulic press (1) to force pump shaft (2) off
bearing housing (3).
16. Place pump shaft (2) in holding fixture (6).
17. Use hydraulic press (1) to force pump shaft
(2) out of inner race (3), spacer sleeve (4) and
angular-contact ball bearing (5).
18. Use hydraulic press (1) and mandrel (2) to
press cylindrical roller bearing (3) out of bearing
housing (4).
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19. Press counterring (1) off bearing housing (3).
20. Use impact extractor to remove shaft seal (2) from
21. Remove all O-rings.
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5.14.5 Engine coolant pump Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning the engine coolant pump
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5.14.6 Engine coolant pump Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Material
Penetrant remover (Standard-Check) 40002 1
Aqueous developer (Standard-Check) 40004 1
Dye penetrant (Standard-Check) 40488 1
Crack-test oil (No. 63) 40475 1
Crack-test paste (UV-Apelux paste 1031) 40483 1
Spare parts
Engine coolant pump
Water pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
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Engine coolant pump Check
Item Findings Task
Check volute and impeller for
cavitation.
Cavitation visible. Replace
Check bearing housing, impeller
and volute with red dye penetrant
for cracks.
Check water pump shaft with
magnetic crack-testing procedure
for cracks.
Check coolant pump shaft for wear
and damage.
Wear
Damage
visible
Recondition: smooth minor
traces of wear with emery cloth.
Replace
Visually inspect sealing surfaces for
wear, pitting and cavitation.
Wear
Pitting
Cavitation
visible
Replace
Check gear for indentations, traces
of wear and damage.
Wear
Indentations
Damage
visible
Replace gear.
Measure bearing seats and
diameters on engine coolant pump,
impeller, seal carrier and bearing
housing and gear with inside and
outside micrometer. Values and
measuring points ( Page 656)
Not dimensionally accurate Replace
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5.14.7 Engine coolant pump Tolerances
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Seal carrier 90.000
K7
0.025 +0.010 1
Angular-contact
ball bearing
outer diam.
90.000 0.015 0
0.025 0.025
Bearing housing
bore
90.000
K7
0.025 +0.010 2
Angular-contact
ball bearing
outer diam.
90.000 0.015 0
0.025 0.025
Angular contact
ball bearing bore
40.000 0.012 0 3
Shaft outer diam. 40.000
k5
+0.002 +0.013
0.002 0.025
Spacer sleeve
bore
40.000
N7
0.033 0.008 4
k5
+0.002 +0.013
0.010 0.046
Bearing housing
bore
80.000
K7
0.021 +0.009 5
Cylindrical roller
bearing
80.000 0.013 0
0.022 0.021
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Cylindrical roller
bearing bore
40.000 0.012 0 6
k5
+0.002 +0.013
0.002 0.025
Gear bore 39.000
H7
0 +0.025 7
s6
+0.043 +0.059
0.018 0.059
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Seal carrier bore 72.000
H8
0 +0.046 1
Shaft seal outer
diam.
72.000 +0.130 +0.230
0.084 0.230
Shaft outer diam. 48.000 0.100 0 2
If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.
Rotary seal
inner diam.
35.000
h8
0.039 0 3
Rotary seal outer
diam.
78.200 0.030 0
0.040 0.100
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Impeller bore 35.000
H5
0 +0.009 4
t5
+0.048 +0.059
0.032 0.050
Rotary seal
Counterring
5
If wear traces are found: Replace components together
s1 : 0.7 to 1.1
s2 : 0.6 to 1.5
s3 : 0.5 to 0.65
s4 : 0.08 to 0.5
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5.14.8 Engine coolant pump Assembly
Special tools
Press-fit tool for angular-contact ball bearings F30378152 1
Press-fit tool for roller bearings F30378153 1
Press-fit tool for shaft seal F30450990 1
Press-in tool for rotary seal F6784612 1
Fixture for bearing housing F6780563 1
Fixture for shaft with bearing F6781573 1
Retaining device F6780561 1
Pliers for snap ring F30002760 1
Material
Ethanol 40250 1
Engine oil
Spare parts
Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring
WARNING
Component is hot.
Risk of burning!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
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Engine coolant pump Assembly
Note: Apply press-in pressure to bearing
outer ring.
1. Use hydraulic press (1) and mandrel (2) to press
cylindrical roller bearing into bearing housing (4).
2. Insert snap ring (2) in groove of bearing
housing (3), using snap ring pliers (1).
3. Check that snap ring (2) fits correctly.
angular-contact ball bearing (3) on to pump
shaft (4).
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spacer sleeve (3) on to pump shaft (4).
inner ring (2) of cylindrical roller bearing on to
pump shaft (3).
Note: Apply press-in pressure to bearing outer
ring (3).
pump shaft into bearing housing (4).
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Note: Make sure that shaft seal (2) is in the
correct position.
8. Insert shaft seal (2) in press-in mandrel (1).
shaft seal into seal carrier (3).
10. Coat O-ring with grease and insert in groove.
11. Place bearing housing (1) in fixture (4).
12. Use screws (2) to install seal carrier on bearing
housing (1) and tighten them evenly.
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13. Heat gear (2) to 200 C.
14. Place bearing housing (3) with seal carrier and
holding fixture (4) on to hydraulic press (1).
15. Use hydraulic press (1) to push heated gear (2) on
to shaft up to stop and hold until shrink connection
between shaft and gear is firm.
16. Coat O-ring on counterring (2) with grease and
insert in bearing housing (2).
17. Clean sliding surface on counterring (2) with
ethanol.
18. Coat inner diameter of bellows seal (1) with low
surface tension water.
19. Clean sliding surface on bellows seal (1) with
ethanol.
20. Fit bellows seal (1) on shaft (4) and use press-in
tool to push it up to the counterring (2).
21. Heat impeller (1) to 210 C.
22. Place engine coolant pump on hydraulic press (1).
23. Place two feeler plates (clearance
S1 = 0.7 mm to 1.1 mm) on seal carrier (3),
arranged at 180 towards one another.
24. Push heated impeller (2) with hydraulic press (1)
until it stops at feeler plates.
25. Measure clearance S1 between impeller (2) and
seal carrier (3) with feeler gauge.
26. If measured value is out of tolerance, determine
the cause and replace components, if necessary.
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27. Set volute (3) down on bearing housing (1)
according to the installation position marking
made before removal.
28. Tighten screws (2).
29. Turn pump shaft to check ease of movement.
30. Measure clearance S2 (0.6 mm to 1.5 mm)
between impeller and volute (3) with feeler gauge.
31. If gap clearance is out of tolerance, determine the
cause and replace components, if necessary.
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5.14.9 Engine coolant pump Installation
Special tools
Material
Engine oil
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Engine coolant pump Installation
2. Coat O-ring (1) with grease.
3. Insert O-ring (1) in groove on bearing housing of
engine coolant pump.
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4. Attach engine coolant pump with lifting gear
and support bracket to crane using a slightly
pretensioned rope.
Note: Make sure that gears are correctly meshed.
5. Install coolant pump (1) in bore on equipment
carrier, ensuring it is correctly positioned.
6. Insert screws (2) and washers and tighten evenly.
7. Remove lifting gear and support bracket.
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5.14.10 Coolant pipework of engine coolant pump, intake side Overview
Elbow with attachments
1 Elbow
2 Plug screw
3 Sealing ring
4 O-ring
5 Screw
6 Washer
7 Holder
8 Screw
9 Washer
10 Drain valve
11 Connector
12 Banjo screw
13 Sealing ring
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Plug-in pipe with flange
1 Plug-in pipe
2 O-ring
3 Flange
4 Screw
5 O-ring
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Coolant pipework
1 Plug-in pipe
2 O-ring
3 Flange
4 Screw
5 O-ring
6 Plug-in pipe
7 O-ring
8 Flange
9 Screw
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5.14.11 Coolant pipework for engine coolant pump, intake side Removal
Preconditions
Coolant pipework for engine coolant pump, intake side Removal
2. Remove all monitoring units installed in coolant lines.
3. Remove coolant pipework for engine coolant pump on intake side as shown in overview drawing ( Page 667).
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5.14.12 Coolant pipework, engine coolant pump, suction side Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning coolant lines
3. Blow dry coolant lines with compressed air and preserve in oil bath.
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5.14.13 Coolant pipework, engine coolant pump, suction side Check
Spare parts
Elbow
Flange
Plug-in pipe
Retainer
Connecting piece
Drain valve
WARNING
Risk of injury!
Coolant pipework, engine coolant pump, suction side, check
Visually inspect retainers, plug
connections and annular grooves on
elbows and connecting lines for wear,
pitting and cavitation.
Wear
Pitting
Cavitation
visible
Corrective work: smooth with
oilstone or crocus cloth.
Replace
wear and damage.
Damaged Corrective work: smooth with
Replace
Pressure-test coolant lines with air
in water bath for leaks as necessary.
Maintain a coolant temperature of min.
= 30 C or max. = 40 C at a test
pressure of 0.5 bar.
Leaking Replace
Check operation of drain valve. Damaged Replace
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5.14.14 Coolant pipework, engine coolant pump, suction side Installation
Material
Engine oil
Spare parts
Sealing rings
O-rings
WARNING
Compressed air.
Risk of injury!
Install coolant lines
2. Blow out coolant lines with compressed air.
3. Coat all O-rings with grease.
4. Install coolant lines without tension using new sealing and O-rings as shown in the overview drawing
( Page 667).
5. Install all monitoring units in coolant lines.
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5.14.15 Coolant pipework after cylinder Overview
Coolant pipework after cylinder Overview
Also applies analogously to 12 V.
1 Connecting piece
2 Screw
3 O-ring
4 Connecting piece
5 Screw
6 Screw
7 O-ring
8 Plug screw
9 Engine coolant collecting line
13 O-ring
14 O-ring
15 O-ring
16 Screw
17 Screw
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5.14.16 Coolant pipework after cylinder Removal
Preconditions
Coolant pipework after cylinder Removal
1. Remove manifolds as per overview drawing ( Page 674).
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5.14.17 Coolant pipework after cylinder Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning coolant pipework after cylinder
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5.14.18 Coolant pipework after cylinder Check
Spare parts
Manifold
Connecting piece
WARNING
Compressed air.
Risk of injury!
WARNING
Hot testing liquid.
Checking coolant pipework after cylinder
Visually inspect plug connections and
annular grooves on connecting piece and
manifold for wear, pitting and cavitation.
Replace
Check manifold with air and corrosion
inhibitor in water bath for leaks. Maintain
a coolant temperature of min. = 30 C or
Leaking Replace
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5.14.19 Coolant pipework after cylinder Installation
Material
Engine oil
Spare parts
O-ring
WARNING
Compressed air.
Risk of injury!
Coolant pipework after cylinder Installation
2. Blow out manifolds with compressed air.
4. Install manifolds free of tension as shown in overview drawing ( Page 674).
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5.14.20 Engine coolant drain lines Overview
Coolant lines
1 Pipe
2 Sealing cone
3 Nut
4 Pipe
5 Pipe
6 Sealing cone
7 Nut
8 Pipe
9 T adapter
10 Sealing cone
11 Nut
12 Retainer
13 Pipe half-clamp
14 Grommet
15 Hex screw
16 Washer
17 Hex nut
18 Hex screw
19 Spacer bushing
20 Retainer
21 Hex screw
22 Spacer bushing
23 Pipe half-clamp
24 Pipe half-clamp
25 Grommet
26 Hex screw
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5.14.21 Engine coolant drain lines Removal
Removing drain lines
1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and externally
mounted components.
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5.14.22 Engine coolant drain lines Cleaning
Special tools
Cleaning brush
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
Remove engine coolant drain lines ( Page 680).
Cleaning engine coolant drain lines
1. Clean coolant drain lines with cleaning agent and cleaning brush.
3. Blow dry coolant drain lines with compressed air and preserve in oil bath.
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5.14.23 Engine coolant drain lines Check
Spare parts
Pipe
Sealing cone
T adapter
Retainer
Spacer bushing
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Checking engine coolant drain lines
Check T piece, retainers and lines for
damage.
Damaged Replace
Pressure-test lines with air and
corrosion inhibitor in water bath for
leaks as necessary. Maintain a coolant
temperature of min. = 30 C or max.
= 40 C at a test pressure of 0.5 bar.
Leaking Replace
Check thread for damage and easy
movement
Damaged or sluggish Corrective work: recut threads
Replace
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5.14.24 Engine coolant drain lines Installation
Material
Engine oil
Spare parts
Grommet
WARNING
Compressed air.
Risk of injury!
Installing engine coolant drain lines
2. Blow out coolant drain lines with compressed air.
3. Install engine coolant drain lines as shown in the overview drawing ( Page 679) without tension and secure
with pipe half-clamps.
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5.14.25 Engine coolant and charge air coolant ventilation Overview
Coolant vent lines (also applies to 16V)
25 Union
30 Sealing ring
45 Vent line
55 Bracket
60 Washer
65 Screw
70 Pipe half-clamp
75 Grommet
80 Screw
90 Union
95 Sealing ring
100 Vent line
110 T-piece
120 Bracket
125 Pipe half-clamp
130 Grommet
135 Screw
145 T-piece
155 Vent line
165 Vent line
170 Union
175 Sealing ring
185 Vent line
195 T-piece
205 Vent line
210 Union
215 Sealing ring
225 Vent line
235 Adapter
240 Sealing ring
260 Vent line
265 Adapter
270 O-ring
305 Bracket
310 Pipe half-clamp
315 Pipe half-clamp
325 Grommet
330 Screw
340 Spacer bush
460 Adapter
465 O-ring
470 Vent line
475 Adapter
480 Sealing ring
490 Threaded union
495 Vent line
505 Bracket
510 Pipe half-clamp
515 Grommet
520 Screw
525 Vent line
535 Bracket
540 Pipe half-clamp
545 Grommet
550 Screw
553 Vent line
555 Vent line
565 Bracket
570 Pipe half-clamp
575 Grommet
580 Screw
585 Spacer bush
590 Pipe half-clamp
595 Grommet
600 Screw
605 Pipe
610 Adapter
615 Sealing ring
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250 T-piece
280 Vent line
290 Union
295 Sealing ring
350 Vent line
355 Threaded union
365 Bracket
366 Screw
367 Washer
370 Pipe half-clamp
375 Pipe half-clamp
380 Grommet
390 Distributor
395 Bracket
400 Screw
402 Plug
403 Plug
410 Threaded union
415 Pipe
420 Union
425 Sealing ring
435 Pipe half-clamp
440 Pipe half-clamp
445 Grommet
450 Screw
621 Union
622 Sealing ring
630 Pipe
640 T-piece
650 Pipe
655 Elbow
700 Threaded union
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5.14.26 Engine coolant and charge-air cooling vent Removal
Preconditions
Engine coolant and charge-air cooling vent Removal
1. Prior to removal of the lines take photos or mark attachments and lines.
2. Remove engine coolant and charge-air cooling vent ( Page 684).
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5.14.27 Ventilation, engine coolant and charge air coolant Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning ventilation, engine coolant and charge air coolant
2. Thoroughly blow out coolant and charge air cooling ventilation with compressed air and preserve in oil bath.
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5.14.28 Ventilation, engine coolant and charge air coolant Check
Spare parts
Pipe
Elbow
Vent line
Distributor piece
T adapter
Retainer
Bracket
Spacer sleeve
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Checking ventilation, engine coolant and charge air coolant
Check lines, elbow, distributor, T piece, retainer,
bracket and spacer sleeve for damage.
Damaged Replace
Check coolant lines for leaks in water bath, using
compressed air and corrosion inhibitor. Maintain a
coolant temperature of min. = 30 C or max. = 40 C
at a test pressure of 0.5 bar.
Leaking Replace
Check thread for damage and easy movement. Damaged or sluggish Corrective work: recut
threads
Replace
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5.14.29 Engine coolant and charge-air cooling vent Installation
Material
Engine oil
Spare parts
Grommet
Pipe clamp half
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
Engine coolant and charge-air cooling vent Installation
2. Install engine coolant and charge-air cooling vent as shown in overview drawing ( Page 684).
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5.14.30 Coolant pipework from/to exhaust turbochargers Overview
1 Adapter
2 Sealing ring
3 Coolant line
4 Adapter
5 Sealing ring
6 Coolant line
7 Holder
8 Pipe half-clamp
9 Pipe half-clamp
10 Grommet
11 Washer
12 Screw
13 Adapter
14 Sealing ring
15 Coolant line
16 Adapter
17 Sealing ring
18 Coolant line
19 Adapter
20 Sealing ring
21 Coolant line
22 Adapter
23 Sealing ring
24 Coolant line
25 Pipe half-clamp
26 Pipe half-clamp
27 Grommet
28 Washer
29 Screw
30 Adapter
31 Sealing ring
32 Coolant line
33 Pipe half-clamp
34 Pipe half-clamp
35 Grommet
36 Washer
37 Screw
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5.14.31 Coolant pipework from/to exhaust turbochargers Removal
Preconditions
Removing coolant lines
2. Remove coolant pipework from/to exhaust turbochargers as shown in overview drawing ( Page 690).
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5.14.32 Coolant pipework from/to exhaust turbochargers Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
CAUTION
Coolant pipework from/to exhaust turbochargers Cleaning
1. Clean parts with cleaning agent and cleaning brush.
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5.14.33 Coolant pipework from/to turbochargers Check
Spare parts
Coolant line
Bracket
Pipe half-clamp
Grommet
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Clean coolant pipework from/to exhaust turbochargers ( Page 692).
Coolant pipework from/to turbochargers Check
Visually check lines, pipe clamp halves,
grommets and brackets for damage.
Damaged Replace
Check coolant lines for leaks in water bath,
using compressed air and corrosion inhibitor.
Maintain a coolant temperature of min. = 30 C
or max. = 40 C at a test pressure of 0.5 bar.
Leaking Replace
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5.14.34 Coolant pipework from/to exhaust turbochargers Installation
Material
Engine oil
CAUTION
CAUTION
Coolant pipework from/to exhaust turbochargers - Installation
1. Before installation, remove all covers.
2. Install coolant pipework from/to exhaust turbochargers as shown in the overview drawing ( Page 690).
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5.14.35 Charge-air coolant pump Overview
1 Charge-air coolant pump
2 O-ring
3 Screw
4 Screw
5 Nut
6 Washer
7 Drain valve
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Charge-air coolant pump Overview
1 Water pump shaft
2 Impeller
3 Bearing housing
4 Seal carrier
5 Volute
6 Spacer sleeve
7 Gear
10 Snap ring
11 Shaft seal
12 Rotary seal
13 O-ring
14 Screw
15 Washer
16 O-ring
17 Screw
18 Washer
19 Plug screw
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5.14.36 Charge-air coolant pump Removal
Preconditions
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Charge-air coolant pump Removal
1. Remove securing screws for charge-air coolant pump as shown in overview drawing ( Page 695).
2. Use crowbar to release charge-air coolant pump from equipment carrier and remove.
3. Mask installation hole for charge-air coolant pump.
4. Remove O-ring from charge-air coolant pump.
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5.14.37 Charge-air coolant pump Disassembly
Special tools
Impact extractor for shaft seal F30450991 1
WARNING
Heavy object.
Risk of crushing!
WARNING
WARNING
Risk of injury!
Charge-air coolant pump Disassembly
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device (1).
5. Use hydraulic spindle (1) and removal tool for
impeller (2) to remove impeller (3) from water
pump shaft.
throughout.
8. Remove bellows seal from pump shaft.
9. Remove charge-air coolant pump from retaining
device.
10. Place bearing housing (3) with pump shaft in vice
with aluminum jaws.
11. Use hydraulic spindle (1) and removal tool (2) to
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housing (1).
13. Remove all bolts (1) using box wrench (2).
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cylindrical roller bearing out of bearing housing (4).
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19. Press out counterring (1).
20. Use impact extractor to remove shaft seal (2) from
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5.14.38 Charge-air coolant pump Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Charge-air coolant pump Cleaning
2. Blow all components thoroughly with compressed air.
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5.14.39 Charge-air coolant pump Tolerances
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Seal carrier 90.000
K7
0.025 +0.010 1
Angular contact
ball bearing
outer
90.000 0.015 0
0.025 0.025
Bearing housing
bore
90.000
K7
0.025 +0.010 2
Angular contact
ball bearing
outer
90.000 0.015 0
0.025 0.025
Angular contact
ball bearing bore
40.000 0.012 0 3
Shaft outer 40.000
k5
+0.002 +0.013
0.002 0.025
Spacer sleeve
bore
40.000
N7
0.033 0.008 4
Shaft outer 40.000
k5
+0.002 +0.013
0.010 0.046
Bearing housing
bore
80.000
K7
0.021 +0.009 5
Cylindrical roller
bearing
80.000 0.013 0
0.022 0.021
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Cylindrical roller
bearing bore
40.000 0.012 0 6
Shaft outer 40.000
k5
+0.002 +0.013
0.002 0.025
Gear bore 39.000
H7
0 +0.025 7
Shaft outer 39.000
s6
+0.043 +0.059
0.018 0.059
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
H8
0 +0.046 1
Shaft seal
outer
72.000 +0.130 +0.230
0.084 0.230
Shaft outer 50.000 0.100 0 2
3 Shaft seal
inner
35.000
h8
0.030 0 0.040 0.100
H5
0 +0.011 4
Shaft outer 35.000
t5
+0.048 +0.059
0.032 0.050
Rotary seal
Counterring
5
s1 : 0.4 to 0.6
s2 : 0.6 to 1.52
s3 : 0.08 to 0.5
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5.14.40 Charge-air coolant pump Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Material
Dye penetrant remover (Standard-Check) 40002 1
Spare parts
Charge-air coolant pump
Pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
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Charge-air coolant pump - Check
Item Findings Task
cavitation.
for cracks.
method, check water pump shaft for
cracks.
Check pump shaft for wear and
damage.
Wear traces
Damage
visible
Replace
Wear
Pitting
Cavitation
visible
Replace
of wear and damage.
Wear traces
Indentations
Damage
visible
Replace gear.
diameters on pump shaft, impeller,
seal carrier and bearing housing
and gear with inside and outside
micrometer. Values and measuring
points ( Page 704)
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5.14.41 Charge-air coolant pump Assembly
Special tools
Installation tool for angular-contact ball bearing F30378152 1
Installation tool for roller bearing F30378153 1
Installation tool for shaft seal F30450990 1
Installation tool for rotary seal F6784612 1
Bearing housing support F6780563 1
Support for shaft with bearing F6781573 1
Support for various mandrels F30275611 1
Material
Ethanol 40250 1
Corrosion inhibitor oil
Spare parts
Snap ring
Shaft seal
Rotary seal
O-ring
WARNING
Component is hot.
Risk of burning!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
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CAUTION
Assembling charge-air coolant pump
Note: Apply pressure to bearing outer ring.
2. Place snap ring (2) in groove of bearing
3. Check that snap ring (2) is correctly seated.
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4. Force angular-contact ball bearing (3) onto pump
shaft (4) using hydraulic press (1) and mandrel (2).
5. Force spacer sleeve (3) onto pump shaft (4) using
hydraulic press (1) and mandrel (2).
6. Force inner ring (2) of cylindrical roller bearing
onto pump shaft (3) using hydraulic press and
mandrel (1).
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Note: Apply pressure to bearing outer ring (3).
pump shaft (2) into bearing housing (4).
Note: Make sure shaft seal (2) is in the correct
position.
8. Insert shaft seal (2) into press-in mandrel (1).
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10. Position intermediate washer in sealing ring
retainer (4).
11. Coat rotary seal (3) with liquid soap and water
(1:2).
rotary seal (3) into seal carrier (4).
13. Clean sliding surface with denatured ethanol
after assembly.
14. Coat O-ring with grease and place into groove.
15. Place bearing housing (1) in holding fixture (4).
housing (1) and tighten evenly.
holding fixture (4) onto hydraulic press (1).
19. Use hydraulic press (1) to push heated gear (2)
onto shaft to stop position and hold until shrink
connection between shaft and gear is fixed.
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20. Coat O-ring of counterring (2) with grease and
insert in bearing housing (2).
21. Clean sliding surface on counterring (2) using
ethanol.
22. Coat inner diameter of bellows seal (1) with
wetted water.
23. Clean sliding surface on bellows seal (1) using
ethanol.
24. Position bellows seal (1) on shaft (4) and push up
to counterring (2) using installation tool.
26. Place charge-air coolant pump on hydraulic
press (1).
27. Use hydraulic press (1) to push heated impeller (2)
onto coolant pump shaft to stop position.
28. Set volute (3) onto bearing housing (1) according
to the installation position marking made before
removal.
30. Turn pump shaft to check ease of movement.
31. Use feeler gauge to check clearance S2 (0.6 mm to
1.5 mm) between impeller and volute (3).
32. If measured clearance is out of tolerance,
determine the cause and replace components,
if necessary.
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5.14.42 Charge-air coolant pump Installation
Material
Grease (Kluthe Hakuform 3010/emulsifier) X00029933 1
Engine oil
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Preparing charge-air coolant pump for installation
charge-air coolant pump.
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Note: Make sure that gears are correctly meshed.
4. Insert charge-air coolant pump (1) in correct
position in bore on equipment carrier.
5. Insert screws (2) with washers.
6. Tighten screws (2) evenly.
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5.14.43 Coolant pipework from/to intercooler Overview
1 Pipe
2 Gasket
3 Screw
4 Holder
5 Screw
6 Nut
7 Coolant line
8 Plug screw
9 Coolant line
10 Rubber sleeve
11 Clamp
12 Holder
13 Spacer washer
14 Screw
15 Coolant line
16 Coolant line
17 Coolant line
18 Rubber sleeve
19 Clamp
20 Holder
21 Spacer washer
22 Screw
23 Gasket
24 Screw
25 Washer
26 Plug screw
27 Sealing ring
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1 Adapter union
2 Sealing ring
3 Drain line
4 Drain valve
5 Holder
6 Screw
7 Washer
8 Pipe half-clamp
9 Grommet
10 Screw
11 Drain line
12 Drain valve
13 Holder
14 Screw
15 Washer
16 Spacer bushing
17 Pipe half-clamp
18 Grommet
19 Screw
20 Drain valve
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5.14.44 Coolant pipework from/to intercooler Removal
Preconditions
Removing coolant pipework
1. Before removing the lines, it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as per overview drawing ( Page 717).
3. Remove sealant.
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5.14.45 Coolant pipework from/to intercooler Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
CAUTION
Cleaning coolant pipework from/to intercooler
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5.14.46 Coolant pipework from/to intercooler Check
Spare parts
Coolant line
Pipe
Rubber sleeve
Gasket
Retainer
Drain valve
Screw
Hex nut
Spacer washer
Spacer bushing
Plug screw
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Checking coolant pipework from/to intercooler
Check sealing surfaces for flatness. Uneven Corrective work: smooth
with oilstone or crocus
cloth.
Replace
Check all components for damage. Damaged Replace
Check thread for easy movement and
damage.
Damaged or sluggish Corrective work: recut
threads
Replace
Pressure-test coolant lines with air and
corrosion inhibitor in water bath for leaks as
necessary. Maintain a coolant temperature
of min. = 30 C or max. = 40 C at a test
Leaking Replace
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5.14.47 Coolant pipework from/to intercooler Installation
Material
Engine oil
White petroleum jelly 40314 1
WARNING
Compressed air.
Risk of injury!
Installing coolant pipework from/to intercooler
2. Blow out coolant pipework from/to intercooler with compressed air.
3. Install coolant pipework from/to intercooler as shown in the overview drawing ( Page 717) and secure with
pipe half-clamps, ensuring the installation is free of tension.
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5.14.48 Coolant pipework with thermostat Overview
Coolant pipework with thermostat
1 Coolant distribution housing
2 Cover
3 O-ring
4 Screw
5 Cover
6 Screw
7 Blind flange
8 O-ring
9 Screw
10 Elbow
11 Gasket
12 Screw
13 O-ring
14 O-ring
15 O-ring
16 Screw
17 Screw
18 O-ring
19 Screw
20 Screw
21 Thermostat housing (high-
temperature circuit)
22 Thermostat insert
23 Sealing ring
24 O-ring
25 Screw
26 Screw
27 O-ring
28 Restrictor
29 Thermostat housing (low-
31 Sealing ring
32 Screw
33 Screw
34 Washer
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5.14.49 Coolant pipework with thermostat Removal
Preconditions
DANGER
Suspended load.
Danger to life!
Removing thermostat housing (high temperature
circuit)
1. Remove screws from flanges (1) and (2).
2. Press the flanges off the sealing surfaces.
3. Remove pipes (3) and (4) as shown in the
4. Remove flange (1).
5. Remove screws (2) from thermostat housing (5).
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6. Replace two screws from thermostat housing with
guide pins (arrowed).
7. Remove thermostat housing from coolant
distribution housing.
8. Remove thermostat inserts, sealing rings, and
O-rings.
Removing coolant distribution housing
1. Screw eyebolts into coolant distribution housing
and suspend the housing using crane and rope.
2. Remove screws and washers for coolant
distribution housing as shown in the overview
3. Using crane and rope, remove coolant distribution
housing from gearcase.
4. Remove O-rings.
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Removing thermostat housing (low temperature circuit)
1. Remove screws from thermostat housing.
2. Remove thermostat housing as shown in the overview drawing ( Page 723).
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5.14.50 Coolant pipework with thermostat Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning coolant pipework with thermostat
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5.14.51 Coolant pipework with thermostat Check
Material
Spare parts
Coolant distribution housing
Thermostat housing
Thermostat insert
Cover
Blind flange
Elbow
Restrictor
WARNING
Compressed air.
Risk of injury!
WARNING
Component is hot.
Risk of burning!
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Checking coolant pipework with thermostat
Check all components for condition
and damage.
Damaged Replace
coolant distribution housing and
thermostat housing for cracks.
Check all mating and sealing
surfaces for wear and damage.
Wear
Damage
visible
Replace
Check support bores of thermostat
elements for damage.
crocus cloth.
Replace
Check threads in coolant distribution
housing for easy movement.
Gaskets, sealing rings and O-rings

Replace
Check coolant and oil chambers
of coolant distribution housing for
leaks with air and corrosion inhibitor
under water. Maintain a coolant
Leaking Replace
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Checking thermostat element (high- and
low-temperature circuits)
Technical data, thermostat elements
Hightemperature circuit Start of
open-
ing (B) =
75 C 2 C
Full open-
ing (A) =
88 C 2 C
Lowtemperature circuit Start of
open-
ing (B)
= 38
C 2 C
Full open-
ing (A)
= 51
C 2 C
Note: The thermostat element must not be in
contact with the container.
1. Suspend the thermostat element by means of a
wire in a container filled with water.
2. Heat water with suitable heat source.
Note: Start-of-opening temperature is stamped
on thermostat insert.
3. Check thermostat insert for start of opening
with heat supply uniform and water constantly
circulated. At approx. 10C below opening
temperature (B), the heating speed must not
exceed 1C per minute.
4. Replace thermostat insert if results of check
are negative.
5. Continue to heat coolant to full-opening
temperature (A).
Result: Thermostat insert must be completely
open after 6 to 8 minutes.
6. Measure stroke travel of thermostat insert. Stroke
must be min. 9.5 mm.
7. If stroke travel is less than 9.5 mm, replace
thermostat insert.
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5.14.52 Coolant pipework with thermostat Installation
Special tools
Eyebolt 000580010000 2
Driving mandrel F30379297 1
Material
Engine oil
Spare parts
O-rings
DANGER
Suspended load.
Danger to life!
CAUTION
Installing coolant distribution housing
1. Coat Orings with petroleum jelly and insert into
grooves (1) in equipment carrier.
2. Insert plug screw (2).
3. Coat mating face of coolant distribution housing on
equipment carrier with Loctite 518 (arrowed).
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Note: When fitting coolant distribution housing
in position, make sure O-rings are not
damaged.
4. Carefully place coolant distribution housing on
equipment carrier with crane and rope and align.
5. Secure coolant distribution housing as shown in
the overview drawing ( Page 723).
Installing thermostat elements
1. Fit sealing ring (2) with flat side to installation
mandrel (1).
2. Drive sealing rings with installation mandrel flush
into thermostat housing.
3. Coat sealing surfaces (arrowed) of thermostat
elements with petroleum jelly.
4. Insert thermostat elements.
6. Insert O-rings in groove.
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Installing thermostat housing (high-temperature
circuit)
1. Insert restrictor (arrowed) into support bore.
2. Install thermostat housing on coolant distribution
housing by means of guide pins.
3. Insert securing screws (2) of thermostat
housing (5).
4. Install flange (1).
5. Install pipelines (3,4) as shown in the overview
6. Install flange (1,2).
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5.15 Power Supply, Engine Side
5.15.1 Battery-charging generator - Overview
1 Battery-charging generator
2 Coupling
3 Carrier
4 Shaft
5 Gear
6 Snap ring
8 Spacer ring
9 Spacer ring
10 Grooved ball bearing
11 Shaft seal
12 O-ring
13 Screw
14 Washer
15 Screw
16 Washer
17 Generator bracket
18 Screw
19 Guard plate
20 Holder
21 Screw
23 Washer
24 Holder
25 Screw
26 Washer
27 Screw
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5.15.2 Battery-charging generator Removal
Special tools
Retaining jig F6782572 1
WARNING
Heavy object.
Risk of crushing!
Removing battery-charging generator
1. Mark and disconnect battery-charging generator
cables.
3. Remove holder (6) and bracket (3).
4. Remove screws (1) and plate (5).
5. Withdraw battery-charging generator (4) from
carrier seating and coupling.
Removing coupling from battery-charging generator
1. Install battery-charging generator in support (1).
2. Remove nut (3).
3. Remove battery-charging generator from support.
4. Remove coupling (2) from support.
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Removing coupling from shaft
1. Remove screw (2).
2. Remove coupling (3).
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5.15.3 Battery-charging generator Disassembly
Disassembling battery-charging generator
Have battery-charging generator overhauled by an authorized workshop only.
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5.15.4 Battery-charging generator Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning battery-charging generator
1. Clean generator with compressed air only; do not use any liquids in cleaning process.
2. Clean all metal parts using cleaner (Snow-White 11-0) and rinse with cleaner (Hakupur 312).
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5.15.5 Battery-charging generator - Check
Spare parts
Coupling
Carrier
Shaft
Gear
Spacer ring
Grooved ball bearing
Gear
Bracket
Guard plate
Holder
Clean battery-charging generator ( Page 738).
Checking battery-charging generator
Item Findings Task
Inspect battery-charging generator
externally for damage.
Damaged Replace
Check all contact and mating
Damaged Recondition: Re-surface with
oil stone or crocus cloth.
Replace
Check thread for ease of movement. No ease of movement Recondition: Re-cut thread(s).
Replace
Check battery-charging generator
drive for abnormal running noises.
Abnormal running noises Contact Service.
Check gear for indentations, signs
of wear and damage.
Indentations
Signs of wear
Damage
visible
Recondition: Re-surface with
crocus cloth or oil stone.
Replace gear.
Check coupling for cracks and
swellings.
Swellings
Cracks
visible.
Replace
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5.15.6 Battery-charging generator Installation
Special tools
Positioning fixture F6557187 1
Material
Engine oil
Spare parts
Shaft seal
WARNING
Heavy object.
Risk of crushing!
Check battery-charging generator ( Page 739).
Installing antifriction bearings and gear on carrier
1. Install antifriction bearings (5-9) on carrier (1).
2. Coat sealing lip of radial-lip shaft seal (10) with
engine oil.
3. Press radial-lip shaft seal into carrier until the
stop is reached.
Note: Heat gear to 180C +20C.
4. Install shaft (3) and gear (4) using the press-in
tool and ensuring that an thrust distance of 0.1 to
0.88 mm is achieved.
5. Coat O-ring (2) with petroleum jelly and position
in groove.
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Installing coupling on shaft
1. Check screws (1) for correct tightening torque
( Page 80).
2. Install coupling (3) ensuring correct positioning.
3. Install positioning fixture to lock the engine.
4. Install screw (2) and tighten to specified tightening
torque ( Page 80).
Installing battery-charging generator drive
1. Install coupling (2) in installation tool (1).
2. Fit generator in installation tool.
3. Position Woodruff key on shaft.
4. Tighten nut to specified tightening torque
( Page 80).
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Installing battery-charging generator
Note: Ensure correct positioning of pins (1).
1. Install battery-charging generator (4) with
coupling (3) to coupling (2) ensuring there is no gap
between the resilient element and the intermediate
plate. Torsion of max. 1.0 mm is permissible.
2. Install holder (6) with bracket (3), ensuring that
parts are not placed under tension.
4. Align battery-charging generator (4).
5. Tighten screws (2) to specified tightening torque
using a torque wrench ( Page 80).
6. Install plate (5) using screws (1).
7. Connect cables as per marking.
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5.16 Mounting/Support
5.16.1 Engine mounting / support Overview
Engine mounting / support
1 Engine mounting bracket 2 Engine mount
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5.16.2 Engine mounting Overview
1 Washer
2 Hex screw
3 Nut
4 Washer
5 Resilient mount
6 Hex screw
7 Washer
8 Engine mounting bracket
9 Dowel pin
10 O-ring
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Engine mounting brackets
2 Screw
4 Screw
5 Screw
6 Nut
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5.16.3 Engine mount Removal
Special tools
Box wrench F30379609 1
DANGER
Engine can tilt over.
Danger to life!
DANGER
Suspended load.
Danger to life!
Engine mount Removal
Note: Replace rubber mounts individually, one
after the other.
1. Install engine supports with engine installed.
2. Insert engine support jackscrews until they make
contact with the foundation and secure the engine
against damping element static deflection.
3. Unscrew all foundation screw fittings on damping
element to be removed.
4. Use locking screws (5) to pull damping elements
together evenly until engine carrier can be
removed.
5. If the gap between base mount and foundation is
not large enough, proceed as follows:
5.1. Remove protective cap (1) and loosen
nut (3).
5.2. Insert height adjusting screw (4) as far as
possible in bearing cap. Make sure not to
twist central buffer. Hold firmly in position at
hexagon (2) if necessary.
6. Remove screws (1,2,4) with washers (3) from
engine mounting bracket.
7. Remove engine mount from crankcase.
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Removing engine support
Note: Remove engine support only if necessary. Make sure that supports are not stressed by engine.
1. Remove screws and washers from engine support ( Page 744).
2. Remove engine support from crankcase.
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5.16.4 Engine mount Cleaning
WARNING
Compressed air.
Risk of injury!
Engine mount Cleaning
Note: Do not allow resilient rubber mounts to come into contact with oil and fuel.
1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Blow out all parts thoroughly with compressed air.
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5.16.5 Engine mounts Check
Material
Spare parts
Engine mounting bracket
Damper mount
Dowel pin
Checking engine mounts
Check engine mounting bracket for cracks
with red penetrant dye.
Sign of cracks Replace
Using the magnetic crack-testing method,
check central buffer for cracks.
Check central buffer for wear and damage. Traces of wear
Damage
Visible
Replace
Check resilient rubber mounts for cracks and
deformation (visual inspection).
Damage
Cracks
Deformation
Visible
Replace
Check thread for ease of movement. Sluggish Rework: recut thread.
Replace
Check bolt-on faces for flatness. Uneven Rework: smooth with oilstone.
Replace
Check grooves for O-rings for damage. Damaged Rework
Replace
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5.16.6 Engine mount Installation
Special tools
Material
Engine oil
Spare parts
O-ring
DANGER
Danger to life!
DANGER
Suspended load.
Danger to life!
DANGER
Installing engine supports
1. Install engine supports with screws and washers as shown in overview drawing ( Page 744).
2. Tighten screws and washers of engine supports.
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A Marking 30 = 6.0 mm buffer clearanceMarking 40
= 8.0 mm buffer clearance
B Unloaded 152.5 mm
C Serial number
D Shore hardness
E Type
F Unloaded 50 mm
G Initial dimension 5 mm
Installing engine mounting bracket with resilient
mount
Note: The resilient mounts are supplied in
preadjusted and locked condition.
1. Prior to installation, check presettings of resilient
mounts. Readjust if required.
2. Degrease engine mounting bracket (3) and flange
mating face (1).
4. Insert O-ring (2) in groove.
5. Chill dowel pins (arrows) in liquid nitrogen.
6. Press dowel pins (arrows) into engine mounting
bracket.
7. Use depth gauge to measure and check blind
hole in crankcase.
Result: Protrusion of dowel pin in engine mounting
bracket must not be greater than depth of blind
hole.
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8. Install assembly pins (1).
9. Mount engine mount on engine mounting bracket
(2).
10. Tighten nut manually.
11. Install engine mounting bracket (2) with screws (3)
and washers as shown in overview drawing
( Page 744).
12. Use torque wrench to tighten screws to specified
13. Remove assembly pins (1).
14. Align base mounts of resilient mounts in
longitudinal direction.
15. Loosen screws on engine supports.
16. Lower engine on to foundation by turning all
jackscrews alternately and evenly.
17. Back off jackscrews.
18. Remove locking screws (6), washers (5) and nuts
(4) or jackscrews and store somewhere safe.
19. Check engine alignment (Height adjustment ).
20. Screw bearing element on to foundation.
21. Use feeler gauge to measure buffer clearance on
resilient mount through measuring groove (3),
readjust central buffer if required.
22. Tighten nut (2) with torque wrench to specified
23. Prevent central buffer from turning by holding
hexagon (1) firmly in place.
Note: Make sure that no oil drips on to rubber
mount.
24. Coat nut mating face and threads of central
buffer with engine oil.
25. Shut down the engine with the locking screws
released for at least 48 hours.
Result: The rubber mounts are compressed.
26. Measure height and height angle.
Result: The dimensions of the shims required to
be installed under the relevant base mount are
defined.
27. After flanging the engine with alternator or
gearbox, align the unit in longitudinal and
transverse direction in accordance with the
alignment instructions.
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A Model RD 314 B 3 mm +0.3 mm
A Model RD 315 HD 4 mm +0.3 mm.
Adjusting central buffer
Note: Target measured values with locking
system removed and engine filled with
engine coolant and engine oil.
1. Remove protective cap and loosen nut.
2. Screw central buffer clockwise into upper stop
position.
3. Unscrew central buffer counterclockwise by the
dimension of clearance (A).
4. Check clearance with feeler gauge through
measuring groove in base mount.
5. Use torque wrench to tighten nut to specified
6. Fit protective cap.
Height adjustment
1. Remove protective cap (1) and release nut (2).
Note: Make sure not to twist central buffer.
2. Lock bearing cap by fitting a locking screw (4).
3. Using height adjusting nut (3), adjust height by
max. 10 mm.
4. If the required height adjustment is still not
achieved, adjust the height by using shims under
the base mount (5).
5. Tighten nut (2) and protect central buffer from
twisting.
6. Seal protective cap and remove locking screw.
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5.17 PTO Systems, Driving End and Free End (Coupling)
5.17.1 Geislinger steel-spring coupling Removal
Special tools
Adjusting mandrels F30379307 2
WARNING
Heavy object.
Risk of crushing!
Removing steel-spring coupling
1. Mount positioning fixture (1) on flywheel.
2. Depending on the position of the steel-spring
coupling, remove screws (2) for lifting device.
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3. Fit lifting device (2) on steel-spring coupling (1)
and attach to crane with a lightly tensioned rope.
4. Remove screws (1) from steel-spring coupling (2)
to flywheel (3).
5. Screw in adjusting mandrels (1).
6. Remove both screws (2) for forcing thread.
7. Install removal device.
8. Using removal tool, force steel-spring coupling off
flywheel.
9. Place steel-spring coupling on a suitable surface.
10. Remove O-rings.
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5.17.2 Geislinger steel-spring coupling Disassembly
WARNING
Heavy object.
Risk of crushing!
Remove Geislinger steel-spring coupling ( Page 754).
Geislinger steel-spring coupling Disassembly
1. Place steel-spring coupling (1) on flange of inner
star.
2. Remove sealing ring screws (2).
3. Press sealing ring (3) with two sealing ring screws
(2) off forcing thread (4) and remove.
4. Turn over steel-spring coupling and place coupling
intermediate section on wooden blocks.
5. Remove hex screws (3).
6. Remove inner star (1) with split bearing and
bearing retainer (4).
7. Raise bearing retainer (4) in direction inner star (1).
8. Remove split bearing by radially withdrawing
the bearing shells.
9. Remove bearing retainer (4) from inner star (1).
10. Remove retaining screws (2) from coupling
intermediate section.
11. Raise side plate from intermediate element spring
unit.
Result: This arrangement permits a complete
inspection of the steel-spring coupling.
Further disassembly is permitted only at the
manufacturers or at a Geislinger Service Point.
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5.17.3 Steel-spring coupling Cleaning
Material
Cleaning agent
Diesel fuel
WARNING
Do not smoke.
WARNING
Compressed air.
Risk of injury!
CAUTION
Steel-spring coupling Cleaning
4. Treat parts with diesel fuel to protect against corrosion.
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5.17.4 Geislinger steel-spring coupling Check
Spare parts
Steel-spring coupling
WARNING
Heavy object.
Risk of crushing!
Clean Geislinger steel-spring coupling ( Page 757).
Geislinger steel-spring coupling Check
Item Findings Task
Check bearing running surfaces for
abrasion.
Abrasion visible Replace damaged parts.
Contact Geislinger or a
Geislinger Service Point.
Check bearing clearance from inner
star to bearing bush and sealing
ring.
Sluggish Recondition: Recut threads.
Replace
Wear test for spring leaves
X max. permissible wear = 2.4 mm
Note: Wear or deformation of the bronze packing
pieces located between the spring leaves
is perfectly normal.
1. Check max. permissible wear X per side of the
inner end of the centre leaf.
2. If wear exceeds the max. permissible wear
dimension X, have all spring packs replaced by
Geislinger or a Geislinger Service Point.
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Wear test for inner star
A max. permissible wear = 1 mm
1. Check maximum wear of groove flanks.
2. If wear exceeds max. permissible dimension A,
replace inner star or recondition groove flank.
Contact Geislinger or a Geislinger Service Point.
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5.17.5 Geislinger steel-spring coupling Assembly
Material
Engine oil
Lubricating grease
Spare parts
Dished washer
O-rings
WARNING
Heavy object.
Risk of crushing!
CAUTION
Check Geislinger steel-spring coupling ( Page 758).
Geislinger steel-spring coupling Assembly
1. The procedure is the same disassembly but in reverse sequence.
2. The following additional instructions must be observed.
2.1. Replace all sealing elements.
2.2. Replace all dished washers.
2.3. Coat bearings and bearing running surfaces with lubricating grease.
2.4. Coat O-rings with petroleum jelly.
2.5. Insert O-rings in grooves.
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5.17.6 Geislinger steel-spring coupling Installation
Special tools
Material
Denaturated ethanol 40250 1
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
CAUTION
CAUTION
Assemble Geislinger steel-spring coupling ( Page 760).
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Installing Geislinger steel-spring coupling
1. Degrease and dry-clean flanging surfaces and
centering devices.
2. Screw adjusting mandrels (1) on to flywheel (2).
3. Coat O-ring (3) with petroleum jelly.
4. Insert O-ring (3) in flywheel.
6. Insert O-ring (1) in groove of steel-spring coupling.
7. Prior to installation, ensure positioning pin (2) is
correctly positioned in relation to flywheel.
8. Install lifting equipment (2) with support bracket on
steel-spring coupling (1).
9. Attach steel-spring coupling (1) and lifting
equipment (2) to crane with a lightly tensioned
rope.
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10. Use crane to position steel-spring coupling (3) on
flywheel (1) and slide on to adjusting mandrels (2).
11. Place entire steel-spring coupling (3) on
flywheel (1).
12. Screw in steel-spring coupling (3) diagonally with
4 screws and dish washers without Loctite 270.
13. Tighten screws to specified tightening torque using
a torque wrench ( Page 80).
14. Remove lifting equipment with support bracket
from steel-spring coupling (3).
15. Install positioning fixture(1) on flywheel (2).
16. Apply Loctite 270 to both sides of dish washers
for screws (3).
17. Insert 8 screws (3) with dish washers in
18. Tighten opposing screws (3) to specified tightening
torque using a torque wrench ( Page 80).
19. Remove the 4 assembly screws.
20. Coat both sides of dish washers for assembly
screws with Loctite 270.
21. Tighten opposing screws to specified tightening
22. Coat both sides of dish washers for slotted
screws (1) with Loctite 270.
23. Insert slotted screws (1) in lifting thread bores
and tighten to specified tightening torque using a
torque wrench ( Page 80).
24. Remove positioning fixture.
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5.17.7 Diaphragm coupling Overview
Diaphragm coupling
1 Diaphragm coupling
2 Screw
3 Washer
4 Washer
5 Washer
6 Screw
7 Screw
8 Washer
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5.17.8 Diaphragm coupling Removal
DANGER
Electrical voltage.
DANGER
Suspended load.
Danger to life!
Diaphragm coupling Removal
1. Secure generator with rope and crane.
2. Remove guard plates from flywheel housing.
3. Remove screws (2) and (7) with washers (8) as per overview drawing ( Page 764).
4. Carefully separate generator from engine.
5. Remove screws (6) as per overview drawing ( Page 764).
6. Remove diaphragm coupling.
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5.17.9 Diaphragm coupling Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove diaphragm coupling ( Page 765).
Diaphragm coupling Cleaning
1. Clean diaphragm coupling with cleaner.
2. Remove cleaner.
3. Rub diaphragm coupling dry with cloth.
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5.17.10 Diaphragm coupling Check
Material
Spare parts
Diaphragm coupling
Washer
WARNING
Heavy object.
Risk of crushing!
Clean diaphragm coupling ( Page 766).
Diaphragm coupling Check
Visually inspect all components for damage
and deformation.
Damaged, deformation visible Replace
Check varnish coat of diaphragm coupling for
damage.
Damaged Replace
Check thread for ease of movement. Sluggish Recut
Replace
Check diaphragm coupling with red penetrant
dye for cracks.
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5.17.11 Diaphragm coupling Installation
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury danger to life!
Take special care when working on a running engine.
WARNING
Heavy object.
Risk of crushing!
Check diaphragm coupling ( Page 767).
Installing diaphragm coupling on generator shaft
Measurement values table
= (pressed + pulled) / 2
X (engine) Y (generator)
No. pressed pulled pressed pulled
1
2
Mean value
1. Fit diaphragm coupling on generator shaft.

2. Install 4 screws (M16 x 60) offset 90 and tighten
crosswise and evenly to specified tightening
torque ( Page 80).
3. Measure dimension Y with generator shaft
pressed.
4. Enter measurement value in table.
pressed.
7. Repeat same measurement procedure at another
position.
8. Enter measurement values in table.
9. Add pressed measurement values, determine
mean value and enter in table.
10. Add pulled measurement values, determine mean
value and enter in table.
11. Determine overall mean value from pressed and
pulled mean values and enter in table.
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12. Measure dimension X with crankshaft pressed.
14. Measure dimension X with crankshaft pulled.
position.
Note: If necessary, disassemble diaphragm
coupling and correct dimension Y by
means of adjusting shims.
21. Check result (specified value Y = X -0.2 to -0.5).
22. Screw in remaining screws (M16 x 60) and tighten
to specified tightening torque ( Page 80).
23. Replace angular plates in generator fan gap with
more easily detachable shims (1).
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24. Screw 2 guide pins (1) into diaphragm coupling
and into flywheel housing and tighten.
Installing generator housing on flywheel housing
1. Secure generator housing (2) with rope (1) and
crane.
2. Join generator housing to flywheel housing (3) and
diaphragm coupling (4) into flywheel, positioning
by means of guide pins (arrow).
3. Fit generator housing screws (M12 x 40).
4. Tighten 2 screws simultaneously, or, if not possible,
then alternately in stages of 30 angle of rotation,
5. Remove guide pins, replace with screws (M12 x
40) and tighten.
6. Support genset on generator side at bearing points.
7. Detach starter from crane.
8. Remove shims from generator fan gap.
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Installing diaphragm coupling with generator shaft
on flywheel
1. Insert screws (1) (M16 x 40) via flywheel housing
openings.
2. Replace guide pins with screws.
3. Tighten 2 opposite screws simultaneously to
4. Use a suitable tool to rotate crankshaft further via
flywheel housing opening until all screws have
been pretightened.
5. Tighten screws, again diagonally and evenly or
alternately in stages of 30 angle of rotation, to
specified tightening torque ( Page 80) .
Concentricity check
Note: If concentricity is above 0.13 mm, remove generator and repeat installation with new installation
position of flywheel and coupling.
1. Measure concentricity of diaphragm coupling (max. permissible 0.13 mm).
2. Note measured values.
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5.17.12 Auxiliary PTO, lateral Overview
Auxiliary PTO, lateral
1 Cover
2 O-ring
3 Screw
5 Gear
6 Housing
7 Screw
8 Washer
9 Sealing ring
10 Flange
11 Guard plate
12 Screw
13 Washer
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Auxiliary PTO externally mounted components
1 Flange
2 Cover
3 O-ring
4 Washer
5 Screw
6 Retainer
7 Screw
8 Washer
9 Screw
10 Washer
11 Plate
12 Retainer
13 Screw
14 Washer
15 Screw
16 Washer
17 Screw
18 Washer
19 Coupling
20 Screw
21 Washer
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Arrangement of installation/removal device for auxiliary PTO flange
1 Connection, SKF oil pressure
hand pump
2 Thrust sleeve
3 Bush
4 Removal/installation device
5 Draw spindle
6 Flange
7 Housing
A Reference dimension = 185 mm
B Push-on dimension = 5.1mm
7.5mm (measured from inner face
of flange to face of gear shaft).
C Check surface = Press-fitted flush
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5.17.13 Auxiliary PTO Removal
Special tools
Installation/removal device, hydraulic pump drive flange F0140044 1
Hydraulic hand pump, 0-3000 bar F6557936 1
WARNING
Removing auxiliary PTO
1. Remove hydropump and coupling with externally
mounted components as shown in the overview
2. Screw draw spindle (3) into flange (2).
3. Install installation/removal device.
4. Screw hydraulic HP fuel line (5) into flange.
5. Install nut (4) and fit by hand.
6. Vent oil pressure hand pump and pipework until
bubblefree oil emerges.
7. Connect HP line to oil pressure hand pump.
8. Read off maximum expansion pressure P
max
at flange.
9. Operate hydraulic hand pump for expanding the
flange taper until expansion pressure is half the
permitted maximum.
10. Maintain this pressure for approx. 5 minutes.
11. Raise expansion pressure in stages of 0.1 x P
max
,
observing holding times of approx. 2 minutes.
Ensure that P
max
is not exceeded.
12. Slowly back off nut (4) until flange (2) is completely
released from shaft.
13. Release hand pump pressure and unscrew
HP line.
14. Remove installation/removal device and draw
spindle.
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15. Remove flange from shaft.
16. Remove housing (1 in the overview drawing
( Page 772)).
Removing shaft with gear
1. Press gear shaft (5 in the overview drawing ( Page 772)) from fit and remove.
2. Unscrew all screws (3 in the overview drawing) from cover (1 in the overview drawing) and remove cover.
3. Press sealing ring (9 in the overview drawing) from fit and remove.
4. Use a suitable puller to remove cylindrical roller bearing (4 in the overview drawing) from shaft.
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5.17.14 Auxiliary PTO Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove auxiliary PTO ( Page 775).
Auxiliary PTO Cleaning
1. Clean all parts with cleaner.
2. Remove cleaner.
3. Blow clean all parts thoroughly with compressed air.
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5.17.15 Auxiliary PTO Check
Material
Fluorescent magnetic powder for magnetic crack-testing method
Spare parts
Cover
Gear
Housing
Flange
Guard plate
Bracket
Plate (optional)
Coupling
Clean auxiliary PTO ( Page 777).
Checking auxiliary PTO
Item Findings Task
Using the magnetic crack-testing method and
fluorescent magnetic powder, check housing,
shaft and gear for cracks.
Visually check sealing surfaces, annular
grooves on cover, flange and housing for wear,
Damaged Reconditioning:
Smooth with emery
cloth or oilstone.
Replace
Check shaft with gear for wear and damage. Slight wear
Damage
visible
Reconditioning:
Smooth with emery
cloth or oilstone.
Replace
Measure bearing seats on shaft with
micrometer.
Limit values exceeded Replace
Visually inspect cylindrical roller bearing
for damage. Always replace during major
overhaul.
Damaged Replace
Check coupling visually for wear and damage. Heavy wear, damage visible Replace
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5.17.16 Auxiliary PTO Installation
Special tools
Installation/removal device assembly, hydraulic pump drive flange F0140044 1
Hydraulic hand pump 0-3000 bar F6557936 1
Draw spindle F6557108 1
Thrust sleeve F6555733 1
Installation tool, radial-lip shaft seal with support F30378655 1
Pressin tool for cylindrical roller bearing 30378656 1
Material
Engine oil
WARNING
Heavy object.
Risk of crushing!
WARNING
Check auxiliary PTO ( Page 778).
Preparing gear shaft
Note: Bearing inner race and outer race are
seen as a single unit and must not be
interchanged.
1. Coat contact surfaces of shaft (4) and track ring (3)
of cylindrical roller bearing with engine oil.
2. Press-fit track ring (3) of cylindrical roller bearing
with jig (1,2) onto gear shaft (4), ensuring it is
gap-free and correctly positioned.
3. Rotate gear shaft and press-fit track ring of
opposite side accordingly.
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Preparing housing
1. Coat O-ring (2) with petroleum jelly and insert in
groove of housing (3).
2. Coat housing bearing with engine oil.
3. Press-fit cylindrical roller bearing (1) with suitable
tool into housing (3).
4. Turn housing through 180.
5. Clean and degrease housing bore for sealing
ring (1).
6. Press-fit sealing ring (1) so that it is flush with
housing (2).
Installing flange
1. Coat O-ring of cover with petroleum jelly.
2. Install cover (1 in the overview drawing
( Page 772)) with screws (3 in the overview
drawing).
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3. Coat cylindrical roller bearing (2) with engine oil.
4. Drive cylindrical roller bearing (2) with jig (1)
carefully into housing bore (3).
5. Insert gear shaft (2) up to stop into cylindrical
roller bearing.
6. Position water cock (1) suitably for housing
installation.
7. Screw 2 guide pins (2) into equipment carrier (1).
8. Position housing (3) with small bore (4) down on
guide pins (2).
9. Insert housing (3) via guide pins (2) into equipment
carrier (1).
10. Secure housing with screws.
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11. Coat contact surfaces of flange bore (1) with
engine oil.
12. Fit flange (1) on gear shaft (2) by hand up to stop.
Note: Push-on dimension = 5.1mm 7.5mm,
measured from inner face of flange
(arrowed) to face of gear shaft (arrowed).
13. Push-on dimension check.
14. Install draw spindle (3), thrust sleeve and jig.
15. Connect HP fuel line (5) to flange (2).
16. Vent hand pumps and pipework until bubblefree oil
emerges.
17. Tighten nut (4).
18. Using hand pump, generate expansion pressure
until flange (2) with nut (4) can be easily screwed
on.
19. Do not exceed maximum permissible expansion
pressure.
20. Retain expansion pressure and screw on flange
21. Release expansion pressure.
22. Remove HP fuel line (5).
23. Leave jig approx. 60 mins. at rest.
24. Remove jig, thrust sleeve and draw spindle.
Installing Centa coupling and externally mounted components
1. Install Centa coupling see Special Publication M060715.
2. Install externally mounted components as shown in the overview drawing ( Page 772).
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5.18 Monitoring and Control System
5.18.1 Monitoring, control and regulation devices Overview
Engine Control Unit (ECU)
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5.18.2 Cabling and engine wiring harnesses Overview
Designation Pin assignment
X2 ECU 4
B1 Camshaft speed
B3 Intake air temperature
B5 Oil pressure
B6 Engine coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
B26 Charge-air coolant temperature
B34 Fuel pressure after filter
B50 Crankcase pressure
F25 Lube oil differential pressure
Engine wiring harness
W2
F46 Leak-off fuel
X3 ECU 4
B33 Fuel temperature
B48 Fuel pressure after HP pump
W3
M8 HP fuel pump actuator
X4 ECU 4
For 8V
Y39.1 to Y39.4 Injectors, engine side A
Y39.11 to Y39.14 Injectors, engine side B
For 12V
For 16V
W4
System cable W003
(power supply)
X5 ECU4
System cable W004
(generator control)
X1 ECU4
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Engine wiring harness W2
1 Wiring harness W2
2 Pressure sensor
3 Pressure sensor
4 Bush
5 O-ring
6 Pressure sensor
7 Pressure sensor
9 Sealing ring
10 Speed sensor
11 Speed sensor
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1 Wiring harness W3 2 Pressure sensor 3 HP fuel pump actuator M8
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A1 Injector Y39.1
A2 Injector Y39.2
A3 Injector Y39.3
A4 Injector Y39.4
A5 Injector Y39.5*
A6 Injector Y39.6*
A7 Injector Y39.7**
A8 Injector Y39.8**
B1 Injector Y39.11
B2 Injector Y39.12
B3 Injector Y39.13
B4 Injector Y39.14
B5 Injector Y39.15*
B6 Injector Y39.16*
B7 Injector Y39.17**
X4 Connector to ECU 4
* Only for 12V and 16V
** Only for 16V
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5.18.3 Engine wiring harnesses Removal
Preconditions
Special tools
WARNING
Hot oil.
WARNING
Coolant is hot and under pressure.
Let the engine cool down.
Removing engine wiring harnesses W2 and W3
1. Identify wiring harness by labeling (near ECU
connector) and determine route.
2. Unscrew bayonet connector at ECU 4 with
connector pliers.
3. Unscrew connectors of connected
sensors/actuators.
Note: Note position of cable clamps/ties. New
cable clamps/ties must be fitted in the
same places when reinstalling.
4. Remove cable clamps/ties (1) secured to the
wiring harness (2) which is to be replaced.
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5. Open and remove all locking clips (1) on all cable
retainers (2) using a screwdriver (see arrow tip for
point of application).
6. Pull wiring harness (3) out of all open cable
retainers.
7. Carefully remove wiring harness.
Removing engine wiring harness W4
connector pliers.
sensors/actuators.
retainers.
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7. Remove cylinder head covers ( Page 419).
8. Unscrew spade lugs (1) on injector (2).
9. Undo cable entry (3) and carefully pull connecting
wires out of the cable entry.
10. Remove wiring harness.
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5.18.4 Engine wiring harness Clean
Material
Cleaner (Hakupur 312 at 2% concentration)
CAUTION
CAUTION
Cleaning engine wiring harness
1. Clean engine wiring harness with cleaning agent.
2. Remove cleaner.
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5.18.5 Engine wiring harness Check
Material
Cable tie
Insulating tape
Heat-shrinkable hose
Spare parts
Checking engine wiring harness
1. The engine governor continuously monitors all engine wiring harnesses.
2. The engine governor detects and reports the following errors to the connected monitoring system:
Defective electrical assemblies
Cabling damage
Short circuits
Sensor values outside of the plausibility range.
3. Carry out following checks and maintenance:
Check engine wiring harness for
cracks, kinks and chafing
Cracks
Kinks
Chafing
visible
Rework: repair using insulating
tape or heat-shrinkable hose.
Replace engine wiring harness.
Check shrink-formed components
for damage.
Damaged Replace shrink-formed components.
Check plug connections for
damages.
Damaged Rework: Straighten plug
connections.
Replace plug connector.
tight seating.
Loose engine wiring harness Re-fix engine wiring harness with
cable tie.
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5.18.6 Engine wiring harnesses Installation
Special tools
Spare parts
Cable clamps/ties
Installing engine wiring harnesses W2 and W3
1. Position the wiring harness (3), but do not press it
into the cable retainers (2) yet.
2. Route wiring harness such that it runs between
connected sensors/actuators without tension.
3. Engage and tighten connectors to
sensors/actuators.
4. Press wiring harness into cable retainers.
5. Press locking clips (1) firmly onto cable retainers
until they are fully engaged.
Note: Fit cable clamps/ties (1) in the same places
when installing.
6. Secure cables/wiring harnesses (2) with cable
clamps/ties (1).
7. Connect bayonet connector to ECU 4.
8. Screw union nut of bayonet connector onto ECU 4
with connector pliers.
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Installing engine wiring harness W4
connected injectors without tension.
3. Press wiring harness into cable retainers. Finally
press the locking clips (1) firmly onto the cable
retainers until they engage audibly.
when installing.
4. Secure cables/wiring harnesses with cable
clamps/ties (1).
7. Insert connecting wires in cable entries (3).
8. Twist the wires four times to a suitable length
before connecting them to the injector.
9. Connect spade lugs (1) on injector (2).
10. Install cylinder head cover ( Page 422).
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5.18.7 Sensors, actuators and injectors Overview
1 F46 (leak-off fuel level) 2 F25 (lube oil differential pressure)
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1 B6 (coolant temperature)
2 B5 (lube oil pressure)
3 B34 (fuel pressure after filter)
4 B33 (fuel temperature)
5 B1 (camshaft speed)
6 B48 (fuel high pressure)
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1 B13 (crankshaft speed) 2 B9 (charge-air temperature) 3 B10 (charge-air pressure)
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1 B50 (crankcase pressure)
2 B7 (lube oil temperature)
3 B26 (charge-air coolant
temperature)
4 B3 (intake air temperature)
The injectors are located belowthe cylinder head covers. Injector replacement and necessary activities (Page 435).
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5.18.8 Sensors, actuators and injectors Removal
WARNING
Do not smoke.
WARNING
Hot oil.
WARNING
Removing temperature sensors (B3, B6, B7, B9,
B26, B33)
1. Always note:
The sensors are identical with regard to
design and electrical function. Removal is
also identical.
Arrangement and position of sensors
( Page 795).
2. Observe the following prior to removal:
B6 (coolant temperature) Task description and safety instructions (Operating Instructions)
B7 (oil temperature) During removal, small amounts of engine oil may emerge. Catch engine
oil in a suitable container.
B33 (fuel temperature) During removal, small amounts of fuel may emerge. Catch fuel in a
suitable container.
3. Release bayonet lock (1) and remove connector
(2).
4. Screw out sensor at nut (3).
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Removing pressure sensors (B5, B10)
1. Always note:
also identical.
( Page 795).
During removal of sensor B5 (oil pressure),
small amounts of engine oil may emerge. Catch
engine oil in a suitable container.
(2).
Removing pressure sensor (B34)
1. Always note:
Arrangement and position of sensor
( Page 795).
During removal of sensor B34 (fuel pressure
after filter), small amounts of fuel may emerge.
Catch fuel in a suitable container.
(2).
1. Always note:
( Page 795).
During removal of sensor B48 (fuel high
pressure), small amounts of fuel may emerge.
(2).
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1. Always note:
( Page 795).
(2).
Removing speed sensors (B1, B13)
1. Always note:
also identical.
( Page 795).
2. Release bayonet lock (1) of speed sensor (2) and
remove connector (3) from engine wiring system.
4. Remove speed sensor (2).
Removing differential pressure monitor (F25)
1. Always note:
( Page 795).
During removal of sensor F25, small amounts of
engine oil may emerge. Catch engine oil in a
suitable container.
2. Release screw (1) of connector and remove
connector (2).
3. Release nut (3) and screw out sensor (4) from
measuring block (6).
4. Remove copper sealing ring (5).
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Removing level probe (F46)
1. Always note:
( Page 795).
2. Release bayonet lock and pull off connector.
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5.18.9 Sensors, actuators and injectors Check
Material
Isopropyl alcohol
Spare parts
Pressure sensor
Pressure monitor
Speed sensor
Temperature sensor
Level monitor
Sensors, actuators and injectors Check
1. Always note:
The governor is able to detect defective electric assemblies, wire breaks, short circuits and deviating
sensor values.
2. Carry out the following checks:
Item Findings Task
Check sensors and actuators for
secure seating.
Loose sensors or actuators. Retighten securing screws.
Check security of plug connections. Loose plug connections. Connect plug connections properly
and tighten.
Check sensors, actuators and
plug connections for mechanical
damage.
Damaged Replace
Check sensors, actuators and plug
connections for contamination (e.g.
oil sludge).
Contamination visible. Clean relevant assembly with
isopropyl alcohol.
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5.18.10 Sensors, actuators and injectors Installation
Material
Spare parts
O-ring
Sealing ring
Adjusting washer
Check sensors, actuators and injectors ( Page 803).
Installing temperature sensors (B3, B6, B7, B9,
B26, B33)
1. Always note:
The sensors are identical with regard to design
and electrical function. Installation is identical.
( Page 795).
3. Insert sensor in bore by hand.
5. Fit connector (2) and tighten bayonet lock (1).
Installing pressure sensors (B5, B10)
1. Always note:
( Page 795).
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Installing pressure sensor (B34)
1. Always note:
( Page 795).
1. Always note:
( Page 795).
1. Always note:
( Page 795).
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Installing speed sensor (B13)
1. Always note:
( Page 795).
3. Determine clearance A see table below. Fit
adjusting washer at installation bore if required.
Clearance A (between sensor and timing wheel)
MDEC 1 mm to 1.3 mm
DDEC 0.5 mm to 1 mm
4. Fit sensor in bore and press in.
5. Tighten sensor (2) with screw (4).
6. Insert connector for speed sensor (2) in bush (3) of
engine wiring system. Tighten bayonet lock (1).
7. If necessary, roll up sensor cable to correct length
and secure with cable clamps.
1. Always note:
( Page 795).
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Installing differential pressure monitor (F25)
1. Always note:
( Page 795).
2. Fit new sealing ring (5).
3. Screw in sensor (4) in bore of measurement
block (6) by hand.
5. Fit connector (2) and tighten screw (1).
Level probe (F46)
1. Always note:
( Page 795).
3. Screw in sensor and tighten nut (1).
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Special Tools 809
6 Special Tools
6.1 Standard tools Overview
Order no. Designation
Use
Quan-
tity
8205891159/00 General tool kit 1
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6.2 Special tools Overview
Part No. Designation / Use Qty.
Y20097353 Endoscope 1
Y20010175 Bore gauge, 275-300 mm 1
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Special Tools 811
Y20002705 C-frame micrometer, 275-300
mm
1
Y20091483 Bore gauge, 160-280 mm 1
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mm
1
mm
1
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Special Tools 813
Y20091481 Bore gauge, 18-100 mm 1
mm
1
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Y20011268 Dial gauge 1
Y20002779 Depth gauge, 500 mm 1
F0099994 Swivel frame 1
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Special Tools 815
F6557935 Hydraulic kit 1
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F6783824 Camshaft bearing removal
device
1
B80146893 Hand pump kit 1
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Special Tools 817
F6557186 Hydraulic screw pretensioner 2
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1
F6553646 Installation/removal tool for
main bearing stud
1
F6555771 Stop device for plug (main oil
gallery)
1
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Special Tools 819
F6555738 Assembly jig for camshaft
bearing
1
F30378754 Assembly mandrel for end
cover
1
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F30450446 Camshaft bearing shrink-on
tool
1
F6555763 Guide bushing for camshaft
bearing shrink-on tool
1
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Special Tools 821
F30026582 Torque wrench, 20-100 Nm 1
F30027340 Ratchet adapter 1
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F6782566 Removal tool for carbon
scraper ring
1
F6557114 Removal tool for cylinder liner 1
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Special Tools 823
F6787880 Press-in tool for cylinder liner 1
Y20000326 Micrometer, 150-175 mm 1
Eyebolts
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T80092075 Eyebolt 4
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Special Tools 825
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1
mm
1
0015890321/00 Retainer 1
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Special Tools 827
T80091102 Bracket 1
F6554714 Guide bushing 1
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F6555724 Support 1
F6557190 Removal tool for main
bearing, driving end
1
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Special Tools 829
B80096717 Lukas cylinder 1
B80146893 Hand pump set 1
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F30378426 Installation tool 1
F6557153 Locating device 1
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Special Tools 831
T80091102 Support bracket 1
F6554714 Guide sleeve 1
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1
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Special Tools 833
T80091105 Lifting gear 1
B80146411 Adapter 1
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1
B80096717 Lucas cylinder 1
F6557191 Press-out tool 1
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Special Tools 835
F30378425 Insertion tool 1
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6
0
0
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1
F30377680 Installation mandrel for
radial-lip shaft seal
1
F6782344 Alignment tool (free end),
equipment carrier
1
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Special Tools 837
F6557946 Guide bushing for equipment
carrier
1
0005800100000 Eyebolt 1
mm
1
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1
mm
1
0015890321/00 Holder 1
Master weights
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6
0
0
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1
Special Tools 839
mm
1
Y20506341 DynaMIC hardness tester 1
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6
0
0
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1
Y20091482 Bore gauge, 100-160 mm 1
F6553644 Crankshaft locating device 2
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6
0
0
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1
Special Tools 841
F6783568 Removal tool for crankshaft
bearing caps
1
F6557936 Hydraulic set 1
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1
B80144827 High-pressure hose 1
B80144838 Distributor 1
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Special Tools 843
Y4341947 Measuring device 1
F6553645 Slide protection 2
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1
F6555764 Press-in tool 1
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1
Special Tools 845
F6783003 Alignment tool 1
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6
0
0
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0
1
F6553649 Installation aid 1
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0
0
0
9
6
0
0
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1
Special Tools 847
F6553647 Installation/removal device 1
F0140440 ZB Installation/removal tool 1
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6
0
0
0
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1
5505890163/00 SKF hydraulic unit 1
5555890063/00 Hand pump set 1
T80091387 Trestle 1
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6
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1
Special Tools 849
F6555788 Adapter 1
F30377999 Impact extractor 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6557134 Assembly sleeve 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 851
Y20001744 Micrometer, 175-200 mm 1
F0140771 Installation/removal tool 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 853
F6557187 Flywheel positioning fixture 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30379300 Adjusting mandrel 2
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 855
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
T80090748 Hook-ended chain sling (4 off) 1
F0140771 Removal/installation device 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 857
T80090748 Hook-ended chain sling
(quadruple branch)
1
F6555766 Barring tool, 8V-16V 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6783293 Barring tool, 20V 1
F6555791 Barring tool for timing disc 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 859
F6555792 Pointer for barring tool 1
Y4341124 Timing disc, free end 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378352 Socket, 22 A/F, conrod screws 1
T80091025 Lifting device for piston
removal, 8V-16V
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 861
removal, 20V
1
F6559604 Sliding block 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378003 Piston-ring pliers 1
F6553635 Assembly jig 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 863
T80091025 Lifting device for pistons,
8V-16V
1
T80091496 Lifting device, 20V 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6557121 Assembly sleeves 1
F30378352 Socket, 22 A/F 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 865
F6555791 Barring tool 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y4341492 Testing device 1
Y4341913 Test mandrel 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 867
F30378352 Socket, WAF 22 conrod
screws
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y20090113 Alignment plug gauge, 11.00
mm H7
1
mm H9
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 869
mm H7
1
mm H7
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
mm H7
1
Y4340442 Check gauge for inlet valve
seat
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 871
Y4340443 Check gauge for exhaust
valve seat
1
Y4343688 Removal tool 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y20000083 C-frame micrometer, 0-25 mm 1
F6553658 Removal tool 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 873
B80144872 Plug 1
plugs
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6783833 Valve spring compressor 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 875
F30377634 Socket 1
F6783749 Tool kit without elliptical
chamfer reconditioning
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6783751 Tool kit (accessory
equipment) for elliptical
1
F6784421 Tool kit for valve-seat insert
removal
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 877
F30450433 Indexable insert 1
F6554300 Mounting plate for valve guide
installation
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30450348 Valve guide extractor 1
F6781747 Valve guide mandrel 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 879
F30091631 Reamer, 19.00 mm for stage
0 cylinder head bore
1
I cylinder head bore
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
II cylinder head bore
1
F30450631 Valve seat contour restoring
tool for exhaust valve with
valve-seatinsert
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 881
tool for inlet valve with
ellipticalchamfer and
with/without valve-seat
insert
1
8205890451/00 Turning handle for valve seat
contour restoring tool
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y4340443 Exhaust valve gauge 1
Y4340442 Inlet valve gauge 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 883
Y4341935 Valve seat test device 1
F30451554 Countersink reamer tool 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30450751 Inserting mandrel for
valve-seat insert, inlet
1
valve-seat insert, exhaust
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 885
F30026582 Torque wrench 20-100 Nm 1
T80090944 Carrying bracket 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
seal plug
1
B80144872 Seal plug 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 887
F6553658 Tightening tool (power
amplifier)
1
F6558582 Alignment tool for 8V and 12V
cylinder heads
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6553648 Alignment tool for 16V and
20V cylinder heads
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 889
Y20044010 Measuring tool for angle of
rotation
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378617 Mandrel, 20 mm 1
F30377862 Guide sleeve for mandrel 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 891
F30271842 Mandrel, 24 mm 1
F30377635 Mandrel, 30 mm 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y20506341 Hardness tester DynaMIC 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 893
0015890321/00 Measuring stand 1
F6553642 Camshaft locating device 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30450435 Camshaft installation/removal
tool
1
F6782970 Guide sleeve for camshaft
8V-16V
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 895
20V
1
F6781676 Guide sleeve for assembly on
driving end
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
driving end
1
free end
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 897
F6780582 Centering sleeve for assembly
on free end
1
F6781676 Guide sleeve for
installation/removal from
driving end
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
driving end
1
free end
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 899
F6780582 Centering sleeve for
free end
1
Y4341124 Graduated disc, free end 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y20010128 Feeler gauge 1
F30028351 Box wrench, 19 mm 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 901
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
8205893261/00 Oilstone 1
T80091799 Lifting equipment for HP
pump
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 903
0005388520 Hot-air gun 1
0135315483 Connector pliers 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30377769 Puller 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 905
F6557991 Puller bracket 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6555197 Lever 1
F6557952 Force-in lever 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 907
F30373588 Crowfoot box wrench for HP
lines
1
F6553674 Retaining device for HP
accumulator installation
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6557185 Alignment tool for HP
accumulator
2
F30379005 Slotted nut screwdriver 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 909
F30379104 Filter wrench 1
F70144375 Vibe jaw 2
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30520703 T torque wrench 1
F30376601 Snap ring pliers 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 911
F70144375 Assembly jaws 2.
F30520703 Tee torque wrench, 10-90 Nm 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y20044010 Angle of rotation measuring
device
1
Y20504961 Dynamometer 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 913
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Test bath
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 915
B80090843 Eyebolt 2
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 917
F6781539 Hydraulic spindle 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6780562 Puller tool for impeller 1
F6780561 Puller tool for gear 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 919
F6781573 Holding fixture 1
F30275611 Carrier for several mandrels 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30450991 Impact extractor for shaft seal 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 921
F30378152 Press-fit tool for
angular-contact ball bearings
1
F30378153 Press-fit tool for roller
bearings
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30450990 Press-fit tool for shaft seal 1
F6784612 Press-in tool for rotary seal 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 923
F6780563 Fixture for bearing housing 1
F6781573 Fixture for shaft with bearing 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6780561 Retaining device 1
F30002760 Pliers for snap ring 1
Cleaning brush
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 925
F30378152 Installation tool for
angular-contact ball bearing
1
F30378153 Installation tool for roller
bearing
1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30450990 Installation tool for shaft seal 1
F6784612 Installation tool for rotary seal 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 927
F6780563 Bearing housing support 1
F6781573 Support for shaft with bearing 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30275611 Support for various mandrels 1
000580010000 Eyebolt 2
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 929
F30379297 Driving mandrel 1
F6782572 Retaining jig 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6557187 Positioning fixture 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 931
F30379609 Box wrench 1
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30379307 Adjusting mandrels 2
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 933
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
6
0
0
0
0
1
F0140044 Installation/removal device,
hydraulic pump drive flange
1
F6557936 Hydraulic hand pump,
0-3000 bar
1
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T
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0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 935
F0140044 Installation/removal device
assembly, hydraulic pump
driveflange
1
F6557936 Hydraulic hand pump
0-3000 bar
1
F6557108 Draw spindle 1
M020124/02E 2009-02 MTU
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0
0
0
9
6
0
0
0
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1
F6555733 Thrust sleeve 1
F30378655 Installation tool, radial-lip
shaft seal with support
1
30378656 Pressin tool for cylindrical
roller bearing
1
M020124/02E 2009-02 MTU
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0
9
6
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1
Special Tools 937
6.3 General workshop equipment Overview
Use
Quan-
tity
F30004455 Open-end wrench 1
F30006068 Double open-end
wrench
1
M020124/02E 2009-02 MTU
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0
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0
0
0
9
2
1
6
0
0
2
Use
Quan-
tity
F30025896 Open end wrench
bit
1
bit
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
9
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1
6
0
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2
Special Tools 939
Use
Quan-
tity
bit
1
bit
1
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0
0
0
0
0
9
2
1
6
0
0
2
Use
Quan-
tity
F30047446 Torque wrench 1
F30450902 Ratchet bit 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
9
2
1
6
0
0
2
Special Tools 941
Use
Quan-
tity
F30501631 Starter wrench 1
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0
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0
9
2
1
6
0
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2
Use
Quan-
tity
5505890921/00 Compression
pressure recorder
1
5505890921/06 Diagram sheets 1
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6
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Special Tools 943
6.4 Measuring tools General overview
Use
Quan-
tity
Y20000088 Outside micrometer 1
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Use
Quan-
tity
Y20000665 Adjusting ring
(9 mm)
1
Y20000918 Depth gauge 1
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0
0
0
0
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1
5
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Special Tools 945
Use
Quan-
tity
Y20001743 Caliper gauge 1
Y20016482 Bore gauge 1
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T
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:
0
0
0
0
0
0
9
2
1
5
0
0
2
Use
Quan-
tity
M020124/02E 2009-02 MTU
T
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0
0
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9
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0
0
2
Special Tools 947
Use
Quan-
tity
M020124/02E 2009-02 MTU
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2
6.5 Tools kits Overview
Part No. Designation
Use
Qty.
F30378882 W4 tool kit for Series
4000
1
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1
Diesel Engine 12V 4000 R41 /
16V 4000 R41 (2)
Instructions for Major Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 959
7 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 961
7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 961
7.1.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 961
7.1.2 Maintenance schedule matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 963
7.1.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965
8 Task Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 967
8.1 Engine Checking condition before a major overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 967
8.2 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 969
8.3 Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 970
8.4 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 973
8.5 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 975
8.6 Engine Run-in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 976
8.7 Initial engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 979
9 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
9.1 Crankcase and Externally Mounted Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
9.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
9.1.2 Crankcase and attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 998
9.1.3 Crankcase Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 999
9.1.4 Crankcase Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
9.1.5 Crankcase Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005
9.1.6 Crankcase Checking upper and lower cylinder liner fit . . . . . . . . . . . . . . . . . . . 1007
9.1.7 Crankcase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010
9.1.8 Crankcase Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016
9.1.9 Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024
9.1.10 Cylinder liner Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1032
9.1.11 Cylinder liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1034
9.1.12 Cylinder liner Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1036
9.1.13 Cylinder liner Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1037
9.1.14 Cylinder liner Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1039
9.1.15 Cylinder liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1042
9.1.16 Oil pan Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1045
9.1.17 Oil pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1047
9.1.18 Oil pan Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048
9.1.19 Oil pan Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1049
M020124/02E 2009-02 MTU
9.1.20 Oil pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050
9.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG) . . . . . . . . . . . . 1053
9.1.22 Engine lifting equipment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1054
9.1.23 Engine lifting equipment Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056
9.1.24 Engine lifting equipment Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1057
9.1.25 Engine lifting equipment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058
9.1.26 Engine lifting equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059
9.1.27 End housing, driving end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060
9.1.28 End housing, driving end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1062
9.1.29 End housing, driving end Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1063
9.1.30 End housing, driving end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1064
9.1.31 End housing, driving end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065
9.1.32 End housing KS Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066
9.1.33 End housing, driving end Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1067
9.1.34 End housing, driving end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069
9.1.35 Crankcase ventilation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1071
9.1.36 Crankcase ventilation Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1074
9.1.37 Crankcase ventilation Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1075
9.1.38 Crankcase ventilation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076
9.1.39 Oil separator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077
9.1.40 Oil separator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1079
9.1.41 Oil separator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1080
9.1.42 Crankcase ventilation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1083
9.2 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1084
9.2.1 Gearcase, free end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1084
9.2.2 Gearcase, free end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086
9.2.3 Gearcase, free end Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088
9.2.4 Equipment carrier free end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1089
9.2.5 Gearcase, free end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1090
9.2.6 Gearcase, free end Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1091
9.2.7 Gearcase, free end Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1092
9.2.8 Gearcase, free end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1095
9.2.9 Gear train, free end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1099
9.2.10 Gear train, free end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1101
9.2.11 Gear train, free end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1102
9.2.12 Gear train, free end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103
9.2.13 Gear train, free end Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105
9.2.14 Gear train, free end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1107
9.2.15 Bearing bushing of idler gear Removal and installation . . . . . . . . . . . . . . . . . . . 1110
9.3 Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112
9.3.1 Running gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112
9.3.2 Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113
9.3.3 Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116
9.3.4 Crankshaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1120
9.3.5 Crankshaft - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1121
9.3.6 Crankshaft Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1122
9.3.7 Crankshaft Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1126
9.3.8 Crankshaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1136
9.3.9 Crankshaft Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1138
M020124/02E 2009-02 MTU
9.3.10 Crankshaft bearing shells - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1140
9.3.11 Crankshaft bearing bore Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1142
9.3.12 Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1145
9.3.13 PTO flange, driving end, flywheel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1153
9.3.14 PTO flange, driving end, flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1155
9.3.15 Radial-lip shaft seal, driving end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1159
9.3.16 Flywheel on PTO flange, driving end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1160
9.3.17 Flywheel on PTO flange, driving end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1161
9.3.18 Radial-lip shaft seal, driving end Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1162
9.3.19 PTO flange, driving end, flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 1163
9.3.20 Crankshaft PTO, Free end Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1167
9.3.21 Vibration damper on PTO, free end Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 1169
9.3.22 Vibration damper on PTO, free end Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1172
9.3.23 Vibration damper on PTO, free end Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 1173
9.3.24 Vibration damper on PTO, free end Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1174
9.3.25 Vibration damper on PTO, free end Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . 1175
9.3.26 Vibration damper on PTO, free end Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1176
9.3.27 Piston and conrod Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1180
9.3.28 Piston and conrod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1182
9.3.29 Piston and conrod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1185
9.3.30 Piston Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1187
9.3.31 Piston Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1188
9.3.32 Piston Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1191
9.3.33 Conrod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1197
9.3.34 Conrod Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1198
9.3.35 Conrod Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1199
9.3.36 Conrod Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1206
9.3.37 Conrod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1210
9.3.38 Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1213
9.3.39 Piston and conrod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1216
9.4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1220
9.4.1 Cylinder head and attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1220
9.4.2 Valve-seat turning machine for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1223
9.4.3 Cylinder head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1228
9.4.4 Cylinder head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1231
9.4.5 Cylinder head Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1233
9.4.6 Cylinder head Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1234
9.4.7 Cylinder head Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1237
9.4.8 Cylinder head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1249
9.4.9 Cylinder head Plug repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1255
9.4.10 Cylinder head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1257
9.4.11 Cylinder head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1262
9.5 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1266
9.5.1 Valve gear Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1266
9.5.2 Camshaft overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1267
9.5.3 Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1268
9.5.4 Camshaft Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1270
9.5.5 Camshaft running surfaces and swing followers Visual inspection . . . . . . . . . . 1271
9.5.6 Camshaft Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1272
M020124/02E 2009-02 MTU
9.5.7 Camshaft Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1275
9.5.8 Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1277
9.5.9 Camshaft drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1284
9.5.10 Camshaft drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1285
9.5.11 Camshaft drive Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1287
9.5.12 Camshaft drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1288
9.5.13 Camshaft drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1289
9.5.14 Camshaft thrust bearing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1290
9.5.15 Camshaft thrust bearing Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1291
9.5.16 Camshaft thrust bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1292
9.5.17 Camshaft thrust bearing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1293
9.5.18 Valve drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1294
9.5.19 Valve drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1297
9.5.20 Valve drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1299
9.5.21 Valve drive Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1301
9.5.22 Valve drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1302
9.5.23 Valve drive Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1305
9.5.24 Valve drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1307
9.5.25 Valve drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1310
9.5.26 Cylinder head cover Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1313
9.5.27 Cylinder head cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1314
9.5.28 Cylinder head cover Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1315
9.5.29 Cylinder head cover Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1316
9.5.30 Cylinder head cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1317
9.6 High Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1318
9.6.1 HP fuel system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1318
9.6.2 HP pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1319
9.6.3 HP pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1321
9.6.4 High-pressure pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1323
9.6.5 High-pressure pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1324
9.6.6 HP pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325
9.6.7 H.P. fuel pump Control block replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1327
9.6.8 Injector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1329
9.6.9 Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1330
9.6.10 Fuel injector disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1333
9.6.11 Injector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1334
9.6.12 Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1335
9.6.13 Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1336
9.6.14 High-pressure line Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1339
9.6.15 HP fuel line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1344
9.6.16 HP fuel line Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1348
9.6.17 HP fuel line Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1349
9.6.18 H.P. fuel line Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350
9.6.19 HP fuel line Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1351
9.6.20 HP fuel line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1354
9.6.21 H.P. fuel system Leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1359
9.7 Low Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1360
9.7.1 Fuel system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1360
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9.7.4 Fuel delivery pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1363
9.7.6 Fuel delivery pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1365
9.7.12 Fuel pipework from fuel delivery pump to fuel filter Overview . . . . . . . . . . . . . . 1371
9.7.13 Fuel lines from fuel delivery pump to fuel filter Removal . . . . . . . . . . . . . . . . . . 1372
9.7.14 Fuel lines from pump to filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1373
9.7.15 Fuel lines from fuel delivery pump to fuel filter Check . . . . . . . . . . . . . . . . . . . . 1374
9.7.16 Fuel lines from fuel delivery pump to fuel filter Installation . . . . . . . . . . . . . . . . . 1375
9.7.17 Fuel duplex filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1376
9.7.18 Fuel duplex filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1377
9.7.19 Fuel duplex filter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1378
9.7.20 Fuel filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1379
9.7.21 Fuel filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1380
9.7.22 Fuel duplex filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1381
9.7.23 Fuel duplex filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1382
9.7.24 Fuel pipework from fuel filter to HP pump Overview . . . . . . . . . . . . . . . . . . . . . 1383
9.7.25 Fuel pipework from fuel filter to HP pump Removal . . . . . . . . . . . . . . . . . . . . . 1384
9.7.26 Fuel pipework from fuel filter to high-pressure pump Cleaning . . . . . . . . . . . . . 1385
9.7.27 Fuel pipework from fuel filter to high-pressure pump Check . . . . . . . . . . . . . . . 1386
9.7.28 Fuel pipework from fuel filter to HP pump Installation . . . . . . . . . . . . . . . . . . . . 1387
9.7.29 Leak-off fuel pipework Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1388
9.7.30 Leak-off fuel line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1390
9.7.31 Leak-off fuel pipework Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1391
9.7.32 Leak-off fuel pipework Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392
9.7.33 Leak-off fuel line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1393
9.8 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1394
9.8.1 Exhaust turbochargers Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1394
9.8.2 Exhaust turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1395
9.8.3 Exhaust turbocharger Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1396
9.8.4 Exhaust turbocharger Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
9.8.5 Exhaust turbocharger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1401
9.8.6 Exhaust turbocharger Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1405
9.8.7 Exhaust turbocharger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407
9.8.8 Exhaust turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1413
9.9 Charge-Air Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1414
9.9.1 Intercooler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1414
9.9.2 Intercooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1416
9.9.3 Intercooler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1417
9.9.4 Intercooler Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1418
9.9.5 Intercooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1420
9.10 Air Intake/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1421
9.10.1 Air intake / air supply Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1421
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9.10.2 Intake housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1422
9.10.3 Intake housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1424
9.10.4 Intake housing Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1425
9.10.5 Intake housing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1426
9.10.6 Intake housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1427
9.10.7 Intake air system to cylinders, left Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1428
9.10.8 Air supply system to cylinders, left-hand side Removal . . . . . . . . . . . . . . . . . . . 1429
9.10.9 Air supply system to cylinders, left Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 1430
9.10.10 Air supply to cylinders, left side Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1431
9.10.11 Air supply system to cylinders, left-hand side Installation . . . . . . . . . . . . . . . . . 1432
9.10.12 Air supply system to cylinders, right Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 1433
9.10.13 Air supply system to cylinders, right-hand side Removal . . . . . . . . . . . . . . . . . . 1434
9.10.14 Air supply system to cylinders, right Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 1435
9.10.15 Air supply to cylinders, RHS Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1436
9.10.16 Air supply system to cylinders, right-hand side Installation . . . . . . . . . . . . . . . . 1437
9.10.17 Air pipework from turbocharger to intercooler Overview . . . . . . . . . . . . . . . . . . 1438
9.10.18 Air pipework from exhaust turbocharger to intercooler Removal . . . . . . . . . . . . 1442
9.10.19 Air supply from turbocharger to intercooler Cleaning . . . . . . . . . . . . . . . . . . . . . 1443
9.10.20 Air ducts from turbocharger to intercooler Check . . . . . . . . . . . . . . . . . . . . . . . 1444
9.10.21 Air pipework from turbocharger to intercooler Installation . . . . . . . . . . . . . . . . . 1445
9.11 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1446
9.11.1 Exhaust system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1446
9.11.2 Exhaust pipework after cylinder head Overview . . . . . . . . . . . . . . . . . . . . . . . . 1447
9.11.3 Exhaust pipework after cylinder head Removal . . . . . . . . . . . . . . . . . . . . . . . . . 1448
9.11.4 Exhaust pipework after cylinder head Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450
9.11.5 Exhaust pipework after cylinder head Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1451
9.11.6 Exhaust pipework after cylinder head Installation . . . . . . . . . . . . . . . . . . . . . . . 1452
9.11.7 Exhaust pipework after exhaust turbocharger Overview . . . . . . . . . . . . . . . . . . 1455
9.11.8 Exhaust pipework after exhaust turbocharger Removal . . . . . . . . . . . . . . . . . . 1457
9.11.9 Exhaust pipework after turbocharger Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1458
9.11.10 Exhaust pipework after exhaust turbocharger Check . . . . . . . . . . . . . . . . . . . . 1459
9.11.11 Exhaust pipework after exhaust turbocharger Installation . . . . . . . . . . . . . . . . . 1460
9.11.12 Exhaust pipework after engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
9.11.13 Exhaust pipework after engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1463
9.11.14 Exhaust pipework after engine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1464
9.11.15 Exhaust pipework after engine Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1465
9.11.16 Exhaust pipework after engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1466
9.12 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1467
9.12.1 Electric starter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1467
9.12.2 Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1469
9.12.3 Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1470
9.12.4 Starter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1471
9.12.5 Starter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1472
9.12.6 Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1473
9.12.7 Flame starting system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1474
9.12.8 Flame starting system Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1476
9.12.9 Flame starting system Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1477
9.12.10 Flame starting system Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1478
9.12.11 Flame starting system Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1479
M020124/02E 2009-02 MTU
9.13 Lube Oil System, Lube Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1480
9.13.1 Lube-oil pump with drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1480
9.13.2 Lube-oil pump with drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1481
9.13.3 Lube-oil pump with drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1482
9.13.4 Lube oil pump with drive Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1483
9.13.5 Lube-oil pump with drive Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484
9.13.6 Lube oil pump with drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1486
9.13.7 Oil filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1488
9.13.8 Oil filter with oil filter housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1490
9.13.9 Oil filter housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1491
9.13.10 Oil filter housing Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1492
9.13.11 Oil filter housing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1493
9.13.12 Oil filter housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495
9.13.13 Oil filter with oil filter housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1497
9.13.14 Centrifugal oil filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1499
9.13.15 Centrifugal oil filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1502
9.13.16 Centrifugal oil filter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1503
9.13.17 Centrifugal oil filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1505
9.13.18 Centrifugal oil filter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1506
9.13.19 Centrifugal oil filter - Bearing clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1507
9.13.20 Centrifugal oil filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1508
9.13.21 Centrifugal oil filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1512
9.13.22 Oil heat exchanger Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1513
9.13.23 Oil heat exchanger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1514
9.13.24 Oil heat exchanger Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1516
9.13.25 Oil heat exchanger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1517
9.13.26 Oil heat exchanger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1519
9.13.27 Oil system in crankcase Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1522
9.13.28 Oil system in crankcase Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1524
9.13.29 Oil pipework in crankcase Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1526
9.13.30 Oil pipework in crankcase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1527
9.13.31 Oil system in crankcase Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1529
9.13.32 Turbocharger oil supply Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1533
9.13.33 Turbocharger oil supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1534
9.13.34 Turbocharger oil supply Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1535
9.13.35 Turbocharger oil supply Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1536
9.13.36 Turbocharger oil supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1537
9.14 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1538
9.14.1 Coolant system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1538
9.14.2 Engine coolant pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1540
9.14.4 Engine coolant pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1543
9.14.5 Engine coolant pump Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1548
9.14.6 Engine coolant pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1549
9.14.7 Engine coolant pump Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1551
9.14.8 Engine coolant pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1554
9.14.10 Coolant pipework of engine coolant pump, intake side Overview . . . . . . . . . . . 1562
9.14.11 Coolant pipework for engine coolant pump, intake side Removal . . . . . . . . . . . 1565
M020124/02E 2009-02 MTU
9.14.12 Coolant pipework, engine coolant pump, suction side Cleaning . . . . . . . . . . . . 1566
9.14.13 Coolant pipework, engine coolant pump, suction side Check . . . . . . . . . . . . . . 1567
9.14.14 Coolant pipework, engine coolant pump, suction side Installation . . . . . . . . . . 1568
9.14.15 Coolant pipework after cylinder Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1569
9.14.16 Coolant pipework after cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1570
9.14.17 Coolant pipework after cylinder Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1571
9.14.18 Coolant pipework after cylinder Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1572
9.14.19 Coolant pipework after cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1573
9.14.20 Engine coolant drain lines Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1574
9.14.21 Engine coolant drain lines Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1575
9.14.22 Engine coolant drain lines Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1576
9.14.23 Engine coolant drain lines Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1577
9.14.24 Engine coolant drain lines Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1578
9.14.25 Engine coolant and charge air coolant ventilation Overview . . . . . . . . . . . . . . . 1579
9.14.26 Engine coolant and charge-air cooling vent Removal . . . . . . . . . . . . . . . . . . . . 1581
9.14.27 Ventilation, engine coolant and charge air coolant Cleaning . . . . . . . . . . . . . . . 1582
9.14.28 Ventilation, engine coolant and charge air coolant Check . . . . . . . . . . . . . . . . 1583
9.14.29 Engine coolant and charge-air cooling vent Installation . . . . . . . . . . . . . . . . . . . 1584
9.14.30 Coolant pipework from/to exhaust turbochargers Overview . . . . . . . . . . . . . . . 1585
9.14.31 Coolant pipework from/to exhaust turbochargers Removal . . . . . . . . . . . . . . . . 1586
9.14.32 Coolant pipework from/to exhaust turbochargers Cleaning . . . . . . . . . . . . . . . . 1587
9.14.33 Coolant pipework from/to turbochargers Check . . . . . . . . . . . . . . . . . . . . . . . . 1588
9.14.34 Coolant pipework from/to exhaust turbochargers Installation . . . . . . . . . . . . . . 1589
9.14.35 Charge-air coolant pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1590
9.14.36 Charge-air coolant pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1592
9.14.37 Charge-air coolant pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1593
9.14.38 Charge-air coolant pump Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1598
9.14.39 Charge-air coolant pump Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1599
9.14.40 Charge-air coolant pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1602
9.14.41 Charge-air coolant pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1604
9.14.42 Charge-air coolant pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610
9.14.43 Coolant pipework from/to intercooler Overview . . . . . . . . . . . . . . . . . . . . . . . . . 1612
9.14.44 Coolant pipework from/to intercooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . 1614
9.14.45 Coolant pipework from/to intercooler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1615
9.14.46 Coolant pipework from/to intercooler Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1616
9.14.47 Coolant pipework from/to intercooler Installation . . . . . . . . . . . . . . . . . . . . . . . . 1617
9.14.48 Coolant pipework with thermostat Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1618
9.14.49 Coolant pipework with thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1619
9.14.50 Coolant pipework with thermostat Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1622
9.14.51 Coolant pipework with thermostat Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623
9.14.52 Coolant pipework with thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 1626
9.15 Power Supply, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1629
9.15.1 Battery-charging generator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1629
9.15.2 Battery-charging generator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1630
9.15.3 Battery-charging generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1632
9.15.4 Battery-charging generator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1633
9.15.5 Battery-charging generator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1634
9.15.6 Battery-charging generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1635
9.16 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1638
M020124/02E 2009-02 MTU
9.16.1 Engine mounting / support Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1638
9.16.2 Engine mounting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1639
9.16.3 Engine mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1641
9.16.4 Engine mount Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1643
9.16.5 Engine mounts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1644
9.16.6 Engine mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1645
9.17 PTO Systems, Driving End and Free End (Coupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1649
9.17.1 Geislinger steel-spring coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1649
9.17.2 Geislinger steel-spring coupling Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1651
9.17.3 Steel-spring coupling Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1652
9.17.4 Geislinger steel-spring coupling Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1653
9.17.5 Geislinger steel-spring coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1655
9.17.6 Geislinger steel-spring coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1656
9.17.7 Diaphragm coupling Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1659
9.17.8 Diaphragm coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1660
9.17.9 Diaphragm coupling Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1661
9.17.10 Diaphragm coupling Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1662
9.17.11 Diaphragm coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1663
9.17.12 Auxiliary PTO, lateral Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1667
9.17.13 Auxiliary PTO Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1670
9.17.14 Auxiliary PTO Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1672
9.17.15 Auxiliary PTO Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1673
9.17.16 Auxiliary PTO Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1674
9.18 Monitoring and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1678
9.18.1 Monitoring, control and regulation devices Overview . . . . . . . . . . . . . . . . . . . . . 1678
9.18.2 Cabling and engine wiring harnesses Overview . . . . . . . . . . . . . . . . . . . . . . . . 1679
9.18.3 Engine wiring harnesses Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1683
9.18.4 Engine wiring harness Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1686
9.18.5 Engine wiring harness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1687
9.18.6 Engine wiring harnesses Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1688
9.18.7 Sensors, actuators and injectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1690
9.18.8 Sensors, actuators and injectors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1694
9.18.9 Sensors, actuators and injectors Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1698
9.18.10 Sensors, actuators and injectors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1699
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1703
10.1 Standard tools Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1703
10.2 Special tools Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1704
10.3 General workshop equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1829
10.4 Measuring tools General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1835
10.5 Tools kits Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1840
M020124/02E 2009-02 MTU
M020124/02E 2009-02 MTU
Diesel Engine 12V 4000 R41 / 16V 4000 R41 (2) Instructions for Major Overhaul 959
Instructions for Major
Overhaul
M020124/02E 2009-02 MTU
M020124/02E 2009-02 MTU
7 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41
7.1 Maintenance
7.1.1 Preface
MTU maintenance concept
The maintenance system for MTU products is based on a preventive maintenance concept. Preventive maintenance
makes possible advance operational planning and ensures high operational availability.
The maintenance schedule is based on the load profile/load factor specified below. The intervals at
which maintenance work is to be performed and the scope of the inspection and maintenance activities
described are based on experience of average use and serve only as a guide. Additional maintenance
work and/or adaptation of maintenance intervals may prove necessary for special applications and technical
requirements. Maintenance personnel charged with carrying out maintenance work must be appropriately
qualified depending on the complexity of the task concerned. The various stages QL1 to QL4 correspond
to the scope of training offered by MTU and the tools included in the kits:
QL1: Operational monitoring and maintenance work which may be performed without disas-
sembling the engine when it is out of operation.
QL3: Maintenance work requiring partial disassembly of the engine.
QL4: Maintenance work requiring complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. The maintenance
services must then be continued in accordance with specified intervals.
The Task numbers stated in the action list identify the various maintenance activities. They serve as a reference
for the scope of parts needed and also appear on the labels of the corresponding spare parts.
Notes on maintenance
Fluids and lubricants specifications, maintenance and replacement interval guidelines and the list of recommended
fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications A001061 and in the fluids
and lubricants specifications of the component manufacturers. They are therefore not listed in the maintenance
schedule (exception: deviations from the Fluids and Lubricants Specifications). Use only fluids and lubricants which
conform to MTU specifications or which are approved by the respective component manufacturers.
The user/customer must perform the following maintenance tasks:
Parts made of rubber or synthetic materials shall be protected from oil, wiped clean with a dry
cloth only, and never cleaned with organic cleaning agents.
Fuel prefilter:
The maintenance interval depends on the degree of fuel contamination. Paper elements in fuel
prefilters must be replaced every 2 years at the latest (task 9998).
Battery:
Battery maintenance depends on their use and prevailing ambient conditions. Battery
manufacturers specifications shall apply.
Manufacturers specifications shall apply to the maintenance of all components not listed in this maintenance schedule.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
according to the Fluids and Lubricants Specifications, MTU Publication No. A001061.
Application group
2A Rail traction
M020124/02E 2009-02 MTU
T
I
M
I
D
:
0
0
0
0
0
0
9
0
1
6
0
0
2
Load profile
Load profile table
Power 100% 90% 75% <15%
Corresponding runtime 10% 15% 15% 60%
M020124/02E 2009-02 MTU
T
I
M
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D
:
0
0
0
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7.1.2 Maintenance schedule matrix
0 - 21,000 Operating hours
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Engine oil filter 2
Engine running
- x
Air filter
-
-
Valve gear
-
X
x x x x x x x x x x x x x x x x x x x x
Fuel filter 2
x x x x x x x x x x x x x x x x x x x x x
- x x x x x x x x x x
Fuel injectors
- x x x
Cylinder chambers
-
X X X
Air filter 2 X X X
-
X X
-
X X
Cylinder head
-
X
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22,000 - 30,000 Operating hours
L
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2
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3
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0
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2
5
,
0
0
0
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6
,
0
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7
,
0
0
0
2
8
,
0
0
0
2
9
,
0
0
0
3
0
,
0
0
0
Engine oil filter 2
Engine running
-
Air filter
- x x x x x x x x x
- x x x x x x x x x
Valve gear
- x x x x x x x x x
Fuel filter 2
x x x x x x x x x
- x x x x x
Fuel injectors
- x x
Cylinder chambers
- x x
Air filter 2
x x
- x
- x
Cylinder head
- x
x
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7.1.3 Maintenance tasks
Table of maintenance tasks
Interval Qual-
ifica-
QL1 Engine oil filter Replace engine oil filter during oil change or at latest after Limit
(years) (Operating Instructions)
.
W1008
QL1 Engine operation Check engine oil level (Operating Instructions ). W0500
Visually check for leaks and general condition of engine. W0501
Check intercooler drain line (if applicable). W0502
Check maintenance indicator of air filter (Operating Instructions). W0503
m
Check telltale bores of HP fuel pump (Operating Instructions). W0504
Check relief bores of coolant pump(s) (Operating Instructions). W0505
Check for abnormal running noises, exhaust gas color (Operating
Instructions) and vibrations.
W0506
Drain water and contaminants at fuel prefilter drain cock (if applicable)
W0507
Check contamination indicator position of fuel prefilter (if applicable)
W0508
QL1 Centrifugal oil filter Centrifugal oil filter (if applicable): Check oil residue layer thickness,
clean and replace filter sleeve (Operating Instructions).
W1009
QL1 Fuel filter Replace fuel filter or fuel filter element (Operating Instructions). W1001
QL1 Valve gear Check valve clearance (Operating Instructions ). W1002
QL1 Belt Drive Check condition and tension of drive belt, (Operating Instructions )
replace if necessary (Operating Instructions).
W1003
QL1 Air filter Replace air filter (Operating Instructions). W1005
QL1 Fuel injectors Replace fuel injectors (Operating Instructions ). W1006
QL1 Cylinder chambers Carry out endoscopic inspection on cylinder chambers (Operating
Instructions ).
W1011
QL3 Exhaust turbocharger Overhaul exhaust turbocharger ( Page 1394). W1038
QL3 Component maintenance Before starting maintenance, drain coolant and flush coolant system
( Page 967).
W2000
Check rocker arm, valve bridge, swing follower and swing follower
support for wear ( Page 1294).
W2001
Clean air supply pipework ( Page 1421). W2002
Clean intercooler and check for leaks ( Page 1414). W2003
Replace HP fuel sensor ( Page 1690). W2004
Overhaul engine coolant pump (Workshop Manual ) and charge-air
coolant pump (Workshop Manual).
W2005
Check engine coolant thermostat and replace thermal actuator
( Page 1618).
W2006
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Interval Qual-
ifica-
Replace charge air coolant thermostat and thermal actuator
( Page 1618).
W2007
Check centrifugal oil filter (if applicable) for wear ( Page 1499). W2009
Overhaul starter ( Page 1467). W2010
Check vibration damper ( Page 1167). W2011
Replace seals on all disassembled components. W2062
QL3 Crankcase breather Crankcase breather: Replace filter or filter element ( Page 1071). W1046
QL3 Cylinder head Overhaul cylinder heads, visually check piston crowns and running
pattern of cylinder liners ( Page 1220).
W1063
QL3 Fuel delivery pump Replace fuel delivery pump ( Page 1361). W1051
QL4 Extended component
maintenance
Perform complete engine disassembly. Inspect engine components
acc. to assembly instructions, recondition or replace as necessary
( Page 970).
W3000
Replace all elastomer components and seals. W3001
Replace piston rings ( Page 1180). W3002
Replace conrod bearings ( Page 1180). W3003
Replace crankshaft bearings ( Page 1113). W3004
Replace cylinder liners ( Page 1032). W3005
Replace auxiliary PTO antifriction bearing ( Page 1629). W3006
Replace HP fuel pump ( Page 1319). W3007
Overhaul generator ( Page 1629). W3042
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Task Schedules 967
8 Task Schedules
8.1 Engine Checking condition before a major overhaul
Before the engine is removed, a brief test should be conducted to assist in evaluating
its condition and running behaviour.
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Deviations from the Engine Acceptance Test Record Data found during the test run provide
valuable information for subsequent overhaul services.
Preparations for putting into operation. (Operating Instructions)
Initial operation, start engine. (Operating Instructions)
Run engine warm.
-
Perform operational checks. (Operating Instructions)
Check operating states with fault code display, assess
discrepancies.
Check exhaust gas color. (Operating Instructions)
Operate engine with adjustable zero-power speed.
-
Check fuel line connections for leaks.
-
Remove cylinder head cover. (Operating Instructions)
Check valve gear lubrication.
-
Take engine oil sample. (Operating Instructions)
Install cylinder head cover. (Operating Instructions)
Check intercooler drain line for leaks. (Operating Instructions)
Analyze engine oil sample (spot test, water content,
dilution with fuel).
MTU test kit
Take engine coolant sample. (Operating Instructions)
Examine engine coolant sample. MTU test kit
Check monitoring system and ECU.
-
Shut down engine. (Operating instructions)
If installed, lower coolant level in expansion tank and
check level switch response.
Drain engine coolant. (Operating instructions)
Fill system with cleaning solution.
-
Flush cooling system.
-
Flush charge air cooling system.
-
Perform endoscopic inspection. (Operating Instructions)
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Task Schedules 969
8.2 Engine Removal
Shut off fuel supply.

Drain engine oil at operating temperature. (Operating Instructions)
Examine oil sludge for metallic residues.

Drain engine coolant. (Operating Instructions)
Wash machinery plant (as required, without chemical
detergent).

Disconnect all connections.

Install non-fibrous plugs and blanking plates to seal all
open connections.

Release engine securing screws.

Remove engine and place on stands.

Attach engine to lifting device in accordance with
transportation regulations.
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8.3 Engine Disassembly
Before disassembling the engine, it is advisable to take photographs from all sides or to make
a record of all components installed on the engine.
Remove PTO system.

Remove intake silencer.

Remove air intake. ( Page 1424)
Mark and disconnect electric cables. ( Page 1683)
Remove exhaust system after engine. ( Page 1463)
Remove exhaust system after exhaust
turbocharger.
( Page 1457)
Remove air pipework to intercooler. ( Page 1442)
Disconnect oil supply to exhaust turbocharger. ( Page 1534)
Remove exhaust turbocharger. ( Page 1395)
Disconnect coolant supply to exhaust
turbocharger.
( Page 1586)
Remove couplings. ( Page 1660)
Remove MDEC.

Remove coolant pipework, low-temperature
circuit.
( Page 1614)
Remove crankcase breather. ( Page 1074)
Remove charge air pipes. ( Page 1429)
Remove intercooler. ( Page 1416)
Remove engine coolant ventilation and
charge-air cooling.
( Page 1581)
Remove exhaust pipework. ( Page 1448)
Remove coolant pipework. ( Page 1570)
Remove centrifugal oil filter. ( Page 1502)
Remove oil cooler. ( Page 1514)
Remove thermostat housing. ( Page 1619)
Remove coolant pipework, high-temperature
circuit.
DM_410_WM_202050_520A
( Page 1565)
Remove coolant pump, low-temperature circuit. DM_410_WM_203050_520A
Remove coolant pump, high-temperature
circuit.
DM_410_WM_202050_520A
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Task Schedules 971
Remove auxiliary PTO ( Page 1670)
Remove fuel pipework from fuel filter to HP
pump.
( Page 1384)
Remove leak-off fuel line. ( Page 1390)
Remove leak-off fuel monitoring system. ( Page 1390)
Remove HP fuel pump. ( Page 1321)
Remove fuel pump, low-temperature circuit. ( Page 1362)
Remove fuel filter. ( Page 1377)
Remove starter. ( Page 1469)
Remove HP fuel lines with HP accumulator. ( Page 1344)
Remove cylinder head covers. ( Page 1314)
Remove valve drive. DM_410_WM_055051_520A
( Page 1297)
Remove fuel injector. ( Page 1330)
Remove cylinder heads. ( Page 1228)
Remove vibration damper. ( Page 1169)
Remove coolant distribution housing. ( Page 1619)
Remove flywheel with timing wheel. ( Page 1155)
Disassemble crankcase. ( Page 1002)
Remove engine mounts. ( Page 1641)
Remove engine lifting attachment. ( Page 1056)
Remove end housing, driving end. ( Page 1062)
Remove oil pan. ( Page 1047)
Remove gearcase, free end. ( Page 1086)
Remove oil pump with drive and pressure
reducing valve.
( Page 1481)
Remove piston and conrod. ( Page 1182)
Remove crankshaft. ( Page 1116)
Remove cylinder liners. ( Page 1034)
Remove oil pipework and oil spray nozzles. ( Page 1524)
device.
( Page 1024)
Remove camshaft drive with timing wheel. ( Page 1285)
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Replace camshaft axial alignment bearing. ( Page 1292)
Remove camshaft. ( Page 1268)
Remove end cover. ( Page 1002)
Remove studs. ( Page 1002)
Remove camshaft bearing bush. ( Page 1002)
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Task Schedules 973
8.4 Engine Assembly
Clean crankcase. ( Page 1005)
Check crankcase. ( Page 1010)
Assemble crankcase. ( Page 1024)
Install cylinder liners. ( Page 1042)
Install camshaft. ( Page 1277)
Install oil system in crankcase. ( Page 1529)
Install crankshaft. ( Page 1145)
Install gearcase, free end. ( Page 1095)
Install end housing, driving end ( Page 1069)
Install piston with conrod. ( Page 1216)
Install lube-oil pump with drive. ( Page 1486)
Install oil pan. ( Page 1050)
device.
( Page 1024)
Install camshaft drive. ( Page 1289)
Install camshaft thrust bearing. ( Page 1292)
Install main oil gallery. ( Page 1024)
Install engine lifting eyes. ( Page 1645)
Install cylinder heads. ( Page 1262)
Install coolant distribution housing. ( Page 1626)
Install leak-off fuel pipework. ( Page 1393)
Install valve gear. DM_410_WM_055051_720A
( Page 1310)
Install vibration damper on PTO, free end. ( Page 1176)
Install PTO flange, flywheel driving end. ( Page 1163)
Install engine lifting attachment. ( Page 1059)
Install fuel injector. ( Page 1336)
Install cylinder head cover. ( Page 1317)
Install thermostat housing. ( Page 1626)
Install oil cooler. ( Page 1519)
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Install HP fuel pump. ( Page 1325)
Install auxiliary PTO ( Page 1674)
Install crankcase ventilation. ( Page 1083)
Install oil filter housing. ( Page 1519)
Install centrifugal oil filter. ( Page 1512)
Install HP fuel line. ( Page 1354)
Install fuel delivery pump. ( Page 1366)
Install fuel filter. ( Page 1382)
Install fuel pipework from fuel filter to HP pump. ( Page 1387)
Install MDEC.

Install coolant pump, high-temperature circuit. DM_410_WM_202050_720A
Install coolant pump, low-temperature circuit. DM_410_WM_203050_720A
Install charge air manifolds. ( Page 1432)
Install starter. ( Page 1473)
Install intercooler. ( Page 1420)
Install coolant venting lines ( Page 1584)
Install coolant pipework, high-temperature circuit. ( Page 1568)
Install exhaust pipework. ( Page 1452)
Install coolant pipework after cylinder. ( Page 1573)
Install coolant pipework from/to intercooler. ( Page 1617)
Install exhaust turbocharger. ( Page 1413)
Install engine coolant drain lines. ( Page 1578)
Install coolant supply to exhaust turbocharger. ( Page 1589)
Install exhaust turbocharger oil supply. ( Page 1537)
Install air pipework to intercooler. ( Page 1445)
Install exhaust system after exhaust turbocharger. ( Page 1460)
Install air intake. ( Page 1427)
Install exhaust pipework after engine. ( Page 1466)
Install couplings. ( Page 1663)
Connect electrical lines. ( Page 1688)
Install intake silencer.

Install PTO system.

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Task Schedules 975
8.5 Engine Installation
Open all connections, remove caps and rubber plugs.

Attach engine at lifting eyes only and install as per
transportation instructions.
Connect coolant lines, fuel lines and engine monitoring
system.

Fill with engine coolant. (Operating instructions)
Fill with charge-air coolant. (Operating instructions)
Change/fill with engine oil. (Operating instructions)
Align engine.

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8.6 Engine Run-in procedure
Running in engine after replacing parts
After replacing pistons, piston rings or cylinder liners, run in the engine according to the respective program.
Correct running in is decisive for the service life and operational reliability of the engine.
To destroy the braking energy, use the alternator or brake.
Power must be transmitted from the engine to the brake by means of a resilient coupling.
Adjust engine operational data
Set temperatures, fuel and intake air in accordance with the temperature values in the
MTU Acceptance Test Record. Note the following:
The coolant temperature depends on the operating range of the coolant thermostat.
The fuel temperature depends on the volume of the day tank, as long as there is no
fuel cooling system available at the test bench.
Note down operational data for power, fuel, oil, coolant, charge air and exhaust gas at every test point (time,
speed and effective power) in the MTU diesel engine factory test log under RUN IN ENGINE.
Install engine on test stand.
-
Connect engine to dynamometer or generator.
-
Connect exhaust gas, coolant and fuel lines.
-
Connect control device to MDEC, DDEC.
-
Connect sensors and measuring lines for measuring
fuel, oil, coolant, charge air and exhaust gas to the
corresponding measuring points.
-
Connect dialog unit to ECU. (Acceptance Test Record)
Fill expansion tank with coolant with 2% corrosion
inhibitor oil up to max. mark.
Fill with charge-air coolant. (Operating Instructions)
Bleed coolant lines until bubble-free coolant emerges. (Operating Instructions)
Check that fuel in service or supply tank is to
specification.
Fill oil system with engine oil. (Operating Instructions)
Prime valve gear with oil. (Operating Instructions)
Check emergency shutdown system.
-
Preheat coolant. (Operating Instructions)
Prime engine oil circuit with external pump.
-
Start engine using ECU. (Operating Instructions)
After approx. 1 minute idling operation, switch off
engine and:
Check oil level. If necessary, top up oil.
Remove valve gear cover and check valve gear
lubrication.
Start engine and check idle speed.
-
Check engine running noises. (Operating Instructions)
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Task Schedules 977
Warm up engine. (Operating Instructions)
Check coolant, oil and fuel lines for leaks. (Operating Instructions)
Run in engine in accordance with run-in program and
record measured values.
Check and enter fuel density and color of exhaust gas.
-
Enter barometric pressure and relative air humidity in
Test Record.
Check engine for abnormal running noises and leaks.
-
Check engine monitoring.
-
Adjust speed-sensitive fuel limiter performance
according to Acceptance Test Record.
(Acceptance test record, Control value sheet)
When the run-in program is completed, run down and
switch off engine.
Cut open one oil filter and check for residues. (Operating Instructions)
Check oil level and prepare engine for measurement
of oil consumption.
-
Carry out acceptance test as per Acceptance Test
Record.
-
Enter operational data in Acceptance Test Record. (Acceptance Test Record)
After completion of acceptance test, run down engine
and switch off.
Carry out measurement of oil consumption. (Operating Instructions)
Start engine.
-
Set engine to operating power in accordance with MTU
Acceptance Test Record.
Switch off engine and carry out six start/stop
procedures.
-
Carry out engine preservation run. (Operating Instructions)
Switch off engine and disable the engine starter.
-
Drain engine oil and coolant. (Operating Instructions)
Take protective measures for sea transportation.
-
Disconnect exhaust gas, coolant, and fuel lines.
-
Disconnect control device to MDEC, DDEC.
-
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Remove sensors and measuring lines and seal
measuring points.
-
Remove engine from test stand.
-
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Task Schedules 979
8.7 Initial engine operation
Carry out services to put the engine into operation. (Operating Instructions)
Preheat engine (optional).

Carry out operational checks. (Operating Instructions)
Check monitoring system and ECU. Contact Service.
Perform test run. (Acceptance test record)
Measure intake depression (only for initial operation). Contact Service.
Measure exhaust backpressure (only for initial
operation).
Contact Service.
Perform after-shutdown service. (Operating Instructions)
For extended out-of-service period:
Carry out external preservation
Disable engine start
Seal air inlet and exhaust outlet
Carry out internal preservation (air, oil, fuel)
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Crankcase
80 Nm
screws
80 Nm
screws
80 Nm
Screw A 60 Nm +6 Nm
Screw B 27 Nm +3 Nm
Screw E 74 Nm +7 Nm
Screw A 42 Nm +4
Screw B 42 Nm +4
Screw C 74 Nm +7
Engine oil
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Task Schedules 981
Crank drive
Max. length: 132 mm
Engine oil
Conrod screws
Sequence:
a Short arm
b Long arm
240 Nm +20 Nm
Sequence:
a Short arm
b Long arm
90 + 10
3 Checking torque
Sequence:
a Short arm
b Long arm
450 Nm +20 Nm
Engine oil
Piston crown screws
0.1 mm.
0.1 mm.
2 Release screws
Molykote G-N Plus
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Cylinder head
1 Tighten 25 Nm
Engine oil
A Exhaust side
B Inlet side
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Task Schedules 983
Valve gear
250 Nm +25 Nm
90 Nm +9 Nm
90 Nm +9 Nm
35 Nm +5 Nm
35 Nm +5 Nm
Engine oil
seal
550 Nm +50 Nm
15 Nm +2 Nm
Engine oil
100 Nm + 10 Nm
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Designation Torque
specifications
Lubricant
Ultra Ultratherm
Exhaust pipework
x 120
42 Nm +4 Nm
P37
Charge air cooling
Starting equipment
Engine oil
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Task Schedules 985
Lube-oil system
Engine oil
8/12/16 V engines
6 Nm +1 Nm
8/12/16 V engines
6 Nm +1 Nm
equipment carrier
100 Nm + 10 Nm
carrier
74 Nm +7 Nm
Engine oil
Mounting / support
42 Nm +4 Nm
350 Nm +35 Nm
carrier
580 Nm +50 Nm
crankcase
74 Nm +7 Nm
crankcase
180 Nm + 18 Nm
Engine oil
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Engine oil
screws
50 Nm
100 Nm + 10 Nm
Engine oil
Screw M 16 x 60 250 Nm +25 Nm
Screw M 20 x 50 500 Nm +50 Nm
Screw M 22 x 55 680 Nm + 68 Nm
Engine oil
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Task Schedules 987
Engine oil
flange
74 Nm +7 Nm
housing
40 Nm +4 Nm
74 Nm +7 Nm
Engine oil
to coupling hub
200 Nm + 10 Nm
thread.
Charge air
Engine coolant
Lube oil
Fuel
Intake air
Charge air coolant
15 Nm to 30 Nm
Pressure sensor for
Lube oil
Charge air
20 Nm to 45 Nm
pressure
30 Nm + 10 Nm
pressure
20 Nm to 45 Nm
oil
27 Nm
Engine oil
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Thread
8.8 M
A
(Nm) 10.9 M
A
(Nm) 8.8 M
A
(Nm) 10.9 M
A
(Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
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Task Schedules 989
A
A
(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
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0
3
8
2
5
0
0
5
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Task Schedules 991
A
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inserted in
Thread
A
(Nm)
AI alloy M
A
(Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
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Task Schedules 993
inserted in
Thread
A
(Nm)
AI alloy M
A
(Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
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A
Thread
A
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
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Task Schedules 995
Thread
A
(Nm)
M10 x 1 15
M16 x 1.5 30
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Thread
A
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M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
1 Union nut
2 Union body
3 O-ring
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9 Task Descriptions
9.1 Crankcase and Externally Mounted Components
9.1.1 Engine layout
Illustration applies analogously to 8/12/16 V 4000 G, C and R
010 Crankcase and add-on components
020 Gear train
030 Running gear
040 Cylinder head
050 Valve gear
070 Fuel system (high-pressure)
080 Fuel system (low-pressure)
100 Exhaust turbocharger
110 Intercooler
120 Air intake / air supply
140 Exhaust pipework
170 Starting equipment
180 Lube oil system
200 Engine cooling system
210 Power supply
220 Cooling air system
230 Mounting system/support
250 PTO systems, driving and free
end (couplings)
500 Monitoring, control and regulating
devices, general electr. equipment
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9.1.2 Crankcase and attachments Overview
Overview of crankcase and attachments
1 Crankcase
2 Camshaft bearing
3 Crankshaft bearings
4 Stud
5 Crankshaft alignment bearing
6 Crankshaft alignment bearing cap
7 Oil pan
8 Block
9 Nut for main bearing cap
10 Socket-head screws
11 Main bearing cap
12 Cylinder liner
13 Oil filler neck
14 Oil dipstick
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9.1.3 Crankcase Overview
Crankcase with cover
1 Crankcase
2 Block
3 Screw
4 Drain valve
5 Dowel pin
6 Cover
7 Stud
8 Plug
9 Sealing ring
10 Blanking plug
11 Screw
12 O-ring
13 Holder
14 Screw
15 O-ring
16 Screw
17 Washer
18 O-ring
19 O-ring
21 Gasket
22 Screw
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Crankcase
1 Crankcase
2 Main bearing cap
3 Main bearing cap
4 Stud *
5 Nut
6 Screw
7 Washer
8 End cover
9 Camshaft bearing
(*) Newly fitted studs must be elongated before initial tightening
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Oil filler neck with oil dipstick
2 Sealing ring
3 Unions
4 Oil dipstick
5 O-ring
6 Cover for oil filler neck
7 Gasket
8 Hex screw
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9.1.4 Crankcase Disassembly
Preconditions
Special tools
Camshaft bearing removal device F6783824 1
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
Removing externally mounted components
1. Remove cover ( Page 999).
2. Remove guide tube ( Page 999).
3. Remove oil filler neck, (not applicable to gas engines) ( Page 999).
4. Remove inspection port cover ( Page 999).
5. Remove all seals and O-rings.
Installing crankcase in crankcase rotation device
1. Attach supports (1) for swivel frame (2) on left
and right sides of crankcase.
2. Lift crankcase with lifting device and ropes.
3. Insert crankcase in swivel frame and secure.
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Removing crankshaft bearing cap and studs
Note: Remove studs only if damaged or
over-elongated. When removing, replace
studs in pairs.
2. Place installation/removal tool (arrow) on studs.
3. Remove respective studs using the
installation/removal tool.
Removing camshaft bearings
2. If only one bearing is replaced, protect the next
bearing (arrow) from damage.
3. Insert jig (6) in camshaft bearing (5).
4. Fit screw (1) and retainer (2) on cylinder (4)
using nut (3).
5. Press camshaft bearing (5) out of crankcase.
6. Follow the same procedure to remove the other
camshaft bearing bushings.
Removing last camshaft bearing with flywheel
housing attached
2. Removal is the same as for removal of the
camshaft bearings, with the difference that jig (1)
is used 3. .
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Removing end cover
Note: Do not drill into end cover. Metal chippings
in the crankcase coolant chamber may
cause local overheating.
2. Use pliers to withdraw plug, taking care that end
cover does not fall into the bore.
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9.1.5 Crankcase Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
CAUTION
Crankcase Cleaning
1. Use cleaner (Hakupur 312) to clean elastomer components.
3. Clean crankcase and all threaded bores and blow clear with compressed air.
Cleaning oil filler neck and oil dipstick
2. Blow oil filler neck and oil dipstick clear with compressed air.
3. Make sure parts are perfectly clean.
Cleaning crankshaft cover
1. Remove sealant from crankcase cover.
2. Clean oil bores thoroughly with a hole brush.
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Cleaning oil bores in crankcase
Note: During a major engine overhaul, or if
metal chippings have got into the engine
oil system.
1. Clean oil and coolant bores thoroughly with a
suitable hole brush. Never use a wire brush!
Cleaning crankshaft bearing cap
2. Clean mating faces on crankshaft bearing cap and
crankcase and blow clear with compressed air.
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9.1.6 Crankcase Checking upper and lower cylinder liner fit
Spare parts
Crankcase
a Area I of upper and lower fits
Checking area I of upper and lower fits
1. Check area I of upper and lower fits for corrosive
pitting.
Result: If corrosive pitting is visible in area I,
2. Check area I of upper and lower fit for hollows.
Result: If hollows in area I are larger than
0.500 mm over max. 30 of the circumference,
machine to repair size. To be carried out only in
3. Check area I of lower fit for recesses.
Result: If recesses are visible in area I, machine to
repair stage. To be carried out only in workshops
authorized by MTU.
a Area II of upper and lower fits
Checking area II of upper and lower fits
1. Check area II of upper fit for corrosive pitting.
Result: If corrosive pitting in area II is larger than
0.600 mm, machine to repair stage. To be carried
out only in workshops authorized by MTU.
2. Check area II of lower fit for corrosive pitting.
Result: If corrosive pitting is visible in area II,
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Exemplary illustrations showing corrosive pitting in
upper and lower fits
1. Upper fit
2. Upper fit
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3. Lower fit
4. Lower fit
5. Lower fit
6. If the assessment of the findings should be
unclear or extreme corrosive pitting was found,
(Contact Service.).
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9.1.7 Crankcase Check
Special tools
Bore gauge, 275-300 mm Y20010175 1
Bore gauge, 160-280 mm Y20091483 1
Bore gauge, 18-100 mm Y20091481 1
Material
Corrosion inhibitor (Pfinder AP 11 F) 40355 1
Spare parts
Crankshaft bearing cap
Studs for main bearing
Socket-head screws for crankshaft bearing cap
Camshaft bearing
Oil filler neck, (not applicable to gas engines)
Oil dipstick
Cover
WARNING
Heavy object.
Risk of crushing!
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WARNING
Risk of injury!
CAUTION
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Crankcase Check
Item Findings Task
Check crankcase for cracks using
surface crack-testing method.
Signs of cracks Contact Service.
to check crankshaft bearing caps for
cracks.
Check contact surface and upper and lower cylinder liner fits in crankcase ( Page 1007).
Check crankcase top for stress
marks, damage and cavitation.
Stress marks
Damage
Cavitation
visible
To be carried out only in workshops
authorized by MTU. Rework
crankcase top.
Check main bearing studs for
damage.
Check socket-head screws for
lateral fixation of crankshaft bearing
cap for damage.
Check camshaft bearing and guide
bushings for wear and damage.
Damaged Replace component (Page 1024).
and fits.
Stress marks Corrective work: Smooth with
Replace
Check all threads for damage. Damaged Recut threads.
Check oil filler neck for damage (not
applicable to gas engine).
Replace
Check that oil dipstick fits correctly
in guide tube and check for damage.
Damaged Replace component. Make sure
that replacement oil dipstick is the
correct version.
Check cover for stress marks and
damage.
Stress marks
Damage
visible
Corrective work
Replace
Use a plastic plug to prevent
each bore from being soiled
until the crankcase has been
assembled.
Use a C-frame micrometer to
measure width of crankshaft bearing
cap at upper and lower fits. Values
( Page 1016)
Values exceeded. Replace cap.
Check stud for damage;
measure length of stud. Values
( Page 1016)
Damaged
Values exceeded
Replace ( Page 1024)
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Checking oil bores in crankcase
Note: As part of every major overhaul or if metal
chips penetrate the engine oil system, all
oil and coolant bores must be checked
for particular cleanness using a cold light
source or endoscope.
1. Check oil supply bores for valve drive at
crankcase, sides A and B.
2. Check main oil supply bores for camshaft and
main bearing in crankcase V.
3. Check oil bores (arrow) in camshaft chamber.
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4. Check oil bores in crankshaft bearing pedestal
(rear arrow) and in main bearings (front arrow).
5. Check all coolant and oil bores for contamination
in the same manner.
6. If the crankcase is then not immediately
reassembled or put back into service:
6.1. Dry oil bores.
6.2. Preserve oil bores.
6.3. Seal oil bores air-tight with suitable plugs.
Measuring bearing cap guides
Note: Bearing cap guides not in swivel
frame (results in measuring errors).
1. Remove crankcase from swivel frame and place
on a flat surface.
2. Using a bore gauge (1), measure bearing
cap guides at upper and lower fits. Values
( Page 1016).
authorized by MTU.
bearing cap guide to next repair size using
a boring mill.
4. Install crankcase in swivel frame.
Measuring crankshaft bearing bore
1. Install and tighten crankshaft bearing cap
according to specifications ( Page 1024).
2. Adjust bore gauge.
3. Using a bore gauge (2), measure the crankshaft
bearing bore (1).
4. Record measured values in data sheet. Measuring
planes as well as values ( Page 1016).
authorized by MTU.
5. If values are exceeded: Machine respective bore
to next repair size using a boring mill.
6. Mark repair stages of a crankcase main bore
with numeral punches.
7. When installing a new crankshaft bearing cap:
mark position of new crankshaft bearing cap
accordingly.
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Measuring camshaft bearing bushing bore.
1. Measure diameter of camshaft bearing
bushing bore ( B) with bore gauge. Values
( Page 1016).
2. If values are exceeded: Remove camshaft bearing
bushing (2) ( Page 1002).
3. After removal of camshaft bearing bushing:
Measure diameter (dia. A) of the main camshaft
bearing bore in the crankcase (1). Record
measured values in data sheet. Values
( Page 1016).
authorized by MTU.
main camshaft bearing bore to next repair size
using a boring mill.
6. Install camshaft bearing bushing ( Page 1024).
Measuring crankcase bores for cylinder liners
1. Measure crankcase bore for cylinder liner in upper
and lower fits with bore gauge.
2. Record measured values in data sheet. Values
( Page 1016).
authorized by MTU.
crankcase bore to next repair size using a
boring mill.
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9.1.8 Crankcase Tolerances
Crankcase bore for crankshaft
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 171.000
H6
171.035
Trans-
verse
ovality
max. 0.050
1 171.500
H6
171.535
Trans-
verse
ovality
max. 0.050
1 Crankcase bore
for crankshaft
bearing
2 172.000
H6
0 +0.025
a
After the crankcase bore has been newly produced, it can be exceeded by 0.015 mm in the a-direction
when reinstalled.
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Crankcase bore for camshaft
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 97.000
H6
1 97.500
H6
Crankcase bore
for camshaft
bearing
2 98.000
H6
0 +0.022
0 97.080
1
Camshaft
bearing, outer
removed
1 97.580
0 +0.050
0.058 0.130
Camshaft
bearing bush
bore
installed
92.012 0 +0.052 2
Camshaft outer
92.000
e7
0.107 0.072
0.084 0.171
a
Coaxiality of left and right bearing
b Between camshaft bearing bores 1 and 2
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Top deck and cylinder liner mating face
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 562.000
1 561.700
1 Cylinder liner
mating face
2 561.400
0.150 +0.050
0 562.500 0.200 +0.200
1
2 Top deck
2
562.200 0.100 +0.100
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Crankcase bore for cylinder liner
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 196.000
H7
1 196.500
H7
Crankcase bore
upper fit
2 197.000
H7
0 +0.046
0 196.000
j6
1 196.500
j6
1
Cylinder liner
upper fit
2 197.000
j6
-0.013 +0.016
0.059 0.016 +0.060
0 189.000
H7
1 189.500
H7
Crankcase bore
lower fit
2 190.000
H7
0 +0.046
0 189.000
f6
1 189.500
f6
2
Cylinder liner
lower fit
2 190.000
f6
-0.079 -0.050
0.050 0.125 +0.060
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Stage marking see reconditioning drawing
Machine all crankcase bores to the same repair size.
Main bearing cap
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 298.000
E9
1 298.500
E9
Bearing cap bed
lower fit
2 299.000
E9
+0.110 +0.240
0 298.000
p6
1 298.500
p6
1
Main bearing
caps
lower fit
2 299.000
p6
+0.056 +0.088
0.022 0.184
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
0 298.000
H7
1 298.500
H7
Bearing cap bed
upper fit
2 299.000
H7
0 +0.052
0 298.000
p6
1 298.500
p6
2
Main bearing
caps
upper fit
2 299.000
p6
+0.056 +0.088
0.004 0.088
3 Screw length 348.000 0.500 +0.500
Main bearing bore
Install main bearing cap in crankcase according to installation instructions.
Measure main bearing bores:
Determine diameters a, b1 and b2 in two measuring planes and calculate the averages for a, b1 and b2.
Check bore roundness:
b2 according to the formula: (b1+b2) /2 a
Vertical ovality greater than (b1+b2) /2 is not permissible.
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Crankcase crankshaft bore coaxiality
a
b 8V: from main bearing 1 to 5 0.060 0.100
c
d 16V: from main bearing 1 to 9 0.120 0.140
e
f applies to collar bearing mating faces
0.100 0.120
g
applies to all bearings
0.010 0.035
h applies to all bearings, non-concave 0.010 0.012
k applies to all bearings // 0.015 // 0.018
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Crankcase camshaft bore coaxiality
a
b 8V: from camshaft bearing 1 to 5 0.060 0.100
c
d 16V: from camshaft bearing 1 to 9 0.120 0.140
e
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9.1.9 Crankcase Assembly
Special tools
Installation/removal tool for main bearing stud F6553646 1
Stop device for plug (main oil gallery) F6555771 1
Assembly jig for camshaft bearing F6555738 1
Assembly mandrel for end cover F30378754 1
Camshaft bearing shrink-on tool F30450446 1
Guide bushing for camshaft bearing shrink-on tool F6555763 1
Material
Sealing paste (Elastosil N189) 50546 1
Screw locking compound Loctite No. 270 40083 1
Engine oil
Dry compressed air
Liquid nitrogen
Spare parts
Gasket
O-ring
O-ring
End cover
Camshaft bearing
Stud
DANGER
Suspended load.
Danger to life!
DANGER
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WARNING
Risk of injury!
CAUTION
CAUTION
Installing end cover
1. End cover and crankcase bore must be free
of grease and dry.
2. Coat end cover seat with Loctite screw locking
compound.
3. Using a mandrel, drive end cover into the
crankcase bore.
4. In case of leaks or sealing surface damage, the
end cover can be swaged in after it has been
driven in with a mandrel.
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Installing camshaft bearings
1. Screw camshaft bearing stop and alignment
device (1) on to locating bore of swing-follower
shafts. Installation sequence: Start at driving end
and continue in succession towards free end.
2. Fit plastic installation mandrel (1) on assembly tool.
3. Chill camshaft bearing bushing in liquid nitrogen.
4. Fit chilled camshaft bearing bushing on assembly
tool so that the spring-loaded locating mandrel
(3) of the assembly tool engages in the oil bore
(arrow) of the camshaft bearing bushing.
5. Withdraw installation mandrel from camshaft
bearing assembly tool.
6. Check position of camshaft bearing oil bore in
assembly tool (arrowed).
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bushing (2) from outside in main bore as far as
it will go. At the same time, the assembly tool
is positioned by the centering and positioning
mandrel.
8. Check that oil bores in bearing bushing and
Installing last camshaft bearing
1. Install camshaft bearing stop and alignment device
from outside on free end of crankcase (2) when
installing last camshaft bearing.
bushing in main camshaft bore up to stop. At the
same time, the assembly tool is positioned by the
centering and positioning mandrel.
3. Check that the oil bores in bearing bushing and
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Inserting studs for crankshaft bearing caps
1. Coat thread of stud (1) on shoulder side with
engine oil.
2. Insert stud (1) with the journal side in the threaded
bore.
3. Insert stud (1) up to stop with installation/removal
device (2) and torque wrench. Tightening torque,
see ( Page 980).
Note: Replace studs only in pairs.
4. For initial fitting of studs, carry out the following
steps:
4.1. Tighten nut up to contact.
Tightening method: elongation.
4.4. Release studs.
4.5. Tighten studs again with hydraulic tensioner.
4.6. Release studs.
1. Install bearing cap ( Page 1145).
2. Crankcase mating face (1) for strip (driving end)
must be dry and free of grease.
3. Coat contact surface with sealing paste (arrows)
and do not forget the end sides.
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4. Align strip (1) on securing screw bores (arrows) in
crankcase (2).
5. Place strip (1) on surface coated with sealing
paste on crankcase.
6. Use socket-head screws (2) to fasten strip (1) on
crankcase (3).
7. Using a straightedge, check the alignment of the
strip to the crankcase. The strip surface must form
a single plane with the crankcase joint so that the
oil pan will fit perfectly.
Installing cover
1. Mating faces on crankcase and cover (2) must be
dry and free of grease.
2. Coat new O-ring (1) with grease and insert
in groove.
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3. Mount assembly jig for cover stop on driving end.
4. Coat mating surface (1) on crankcase with surface
sealant.
5. Coat new O-rings (arrowed) with grease and insert
in oil transfer bores.
6. Insert assembly pins (2) in the crankcase at two
diagonally opposite corner points.
7. Use lifting device to connect cover to assembly
pins and lower.
8. Align cover to assembly jig stop.
9. Tighten screws in accordance with tightening
sequence.
8V 1-18
12V 1-26
16V 1-34
20V 1-42
10. Remove assembly device.
11. Coat O-ring with grease and fit on plug (1).
12. Insert plug in oil gallery and secure with lug (2).
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Removing crankcase form swivel frame
1. Attach lifting appliance and lifting ropes to
crankcase. Make sure that lifting ropes are
tensioned evenly.
2. Release crankcase from swivel frame and lift out.
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9.1.10 Cylinder liner Overview
Overview of cylinder liner with scraper ring
1 Cylinder liner 2 Carbon scraper ring 3 Sealing ring
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Cylinder liner with scraper ring in crankcase
1 Carbon scraper ring
2 Cylinder liner
3 Crankcase
4 Sealing ring
5 Sealing ring
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9.1.11 Cylinder liner Removal
Special tools
Removal tool for carbon scraper ring F6782566 1
Removal tool for cylinder liner F6557114 1
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Removing carbon scraper ring
1. Mount removal tool (3) on cylinder liner (1).
2. Remove carbon scraper ring (2) with removal tool
(3) from cylinder liner fit (1).
3. Remove removal tool (3).
4. Remove piston and conrod ( Page 1182).
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Cylinder liner Removal
1. Mark installation position of cylinder liner to
crankcase with a marker pen (arrowed).
2. Insert removal tool into cylinder liner.
3. Position removal tool at lower collar of cylinder
liner. Take care not to damage the oil spray nozzle.
4. To avoid tensioning the liner, only place fork in
position lightly.
5. Rotate the removal tool spindle until the cylinder
liner is released from the crankcase bore.
6. Remove removal tool.
7. Remove cylinder liner from crankcase.
8. Remove sealing rings from cylinder liner.
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9.1.12 Cylinder liner Cleaning
Material
WARNING
WARNING
Compressed air.
Risk of injury!
CAUTION
Cylinder liner Cleaning
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9.1.13 Cylinder liner Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Material
Spare parts
Cylinder liner
Carbon scraper ring
WARNING
Heavy object.
Risk of crushing!
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Cylinder liner Check
Item Findings Task
Check cylinder liner with magnetic
crack testing method.
Check outer wall for corrosive
pitting.
Pitting visible. Replace
wear and damage.
Stress marks
Damage
visible
oilstone.
Replace
Check carbon scraper ring for
scoring and pitting.
Scores
Pitting
visible
Replace
Check floating mount of the carbon
scraper ring in the cylinder liner.
Signs of jamming Measure cylinder liner.
Replace carbon scraper ring.
Check cylinder liner running surface
for scores and pitting.
Scores
Pitting
visible
Replace
Check reversal point of first piston
ring for wear.
Wear visible. Replace cylinder liner.
Measure cylinder liner bore with
bore gauge and dial gauge.
Measurement plane and values
( Page 1039)
Values exceeded. Replace
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9.1.14 Cylinder liner Tolerances
anced
size
Basic
size
lower
upper
min.
max.
min.
max.
0 196.000
H7
1 196.500
H7
Crankcase bore
upper fit
2 197.000
H7
0 +0.046
0 196.000
j6
1 196.500
j6
1
Cylinder liner
upper fit
2 197.000
j6
-0.013 +0.016
0.059 0.016 +0.060
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anced
size
Basic
size
lower
upper
min.
max.
min.
max.
0 189.000
H7
1 189.500
H7
Crankcase bore
lower fit
2 190.000
H7
0 +0.046
0 189.000
f6
1 189.500
f6
2
Cylinder liner
lower fit
2 190.000
f6
-0.079 -0.050
0.050 0.125 +0.060
Cylinder liner ID 170.000
H7
0 +0.040 3
Scraper ring
OD
170.000
g7
-0.054 -0.014
0.014 0.094
4 Scraper ring ID 164.000
H8
0 +0.063
5 Cylinder liner ID
- installed
165.000
H7
0 +0.040
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Cylinder liner
anced
size
Basic
size
lower
upper
min.
max.
min.
max.
0 13.800
1 14.100
1
2 14.400
0.100 0
Reconditioning instructions:
In case of cavitation at upper and/or lower fit of the crankcase bore:
Introduce next repair stage and install cylinder liner of corresponding stage.
Machine cylinder liner mating face on crankcase.
To be carried out only in workshops authorized by MTU.
Check scraper ring OD and ID when fitted.
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9.1.15 Cylinder liner Installation
Special tools
Press-in tool for cylinder liner F6787880 1
Bore gauge, 160-280 mm Y20091483 1
Micrometer, 150-175 mm Y20000326 1
Material
Engine oil
Spare parts
Sealing ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Installing cylinder liner
1. Clean cylinder liner, ensuring that the lower fit and
chamfer are dry and free of grease.
2. Coat sealing rings (2) with grease.
Note: The flat side of the sealing ring must be in
contact with the cylinder liner.
3. Fit sealing rings (2) in grooves on cylinder liner (1).
Note: Note marking when re-installing used
cylinder liners; the installation position is
irrelevant when installing new cylinder
liners.
4. Insert cylinder in the same installation position as
prior to removal in accordance with the marking on
liner and crankcase.
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5. On the opposite side, insert screws (1) of press-in
tool into threaded bores for cylinder head screws.
6. Fit pressure plate (3) on cylinder liner.
7. Rotate spindle (2) clockwise to insert cylinder liner
in crankcase bore.
Measuring cylinder liner ID
1. Adjust bore gauge and dial gauge with micrometer
to basic cylinder liner bore dimension. Value and
measurement planes ( Page 1039).
2. Measure cylinder liner bore with bore gauge.
4. If out-of-round is measured:
4.1. Remove cylinder liner.
4.2. Remeasure cylinder liner bore and outer
diameter.
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Note: Insert carbon scraper ring after installing
piston ( Page 1216).
1. Spray cylinder liner and carbon scraper ring
with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
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9.1.16 Oil pan Overview
1 Oil pan
2 Rubber profile
3 Hex bolt
4 Washer
5 Hex bolt
6 Washer
7 Plug
8 Sealing ring
9 Flange
10 Gasket
11 Hex bolt
12 Hex bolt
13 Washer
14 Suction basket
15 Hex bolt
16 Washer
17 Plug-in pipe (suction pipe)
18 O-ring
19 Connecting piece
20 Hex bolt
21 Washer
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View from free end
1 Hex bolt 2 Washer 3 Oil pan
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9.1.17 Oil pan Removal
Special tools
Eyebolts
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
Oil pan Removal
1. Install the engine in the swivel support and
rotate it 180.
2. Remove hex bolts from oil pan (3).
3. Remove plugs on end faces and install eyebolts
(2).
4. Raise oil pan (3) with hook-ended chain sling (1)
and crane and lower onto suitable support.
5. Remove flanges on end faces.
6. Remove rubber profile.
Removing suction basket
1. Remove hex bolts (5) from connecting piece (2).
2. Remove connecting piece (2) with plug-in pipe (1).
3. Remove plug-in pipe (1) from connecting piece (2).
4. Remove O-rings.
5. Remove hex bolts (4) from suction basket (3).
6. Remove suction basket (3).
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9.1.18 Oil pan Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Oil pan Cleaning
2. Thoroughly blow out oil pan and all threaded bores with compressed air.
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9.1.19 Oil pan Check
Material
Red dye penetrant for surface crack test procedure
Spare parts
Oil pan
Cover
Gasket
Suction basket
Plug-in pipe
Connector
WARNING
Heavy object.
Risk of crushing!
Clean oil pan ( Page 1048).
Oil pan Check
Item Findings Task
Cracktest the oil pan using the
surface cracktesting method and red
penetrant dye.
Crack indication Recondition: Contact Service.
Replace
Check mating face of oil pan with
crankcase for surface irregularities.
Surface irregularity above 0.2 mm Recondition mating face.
Check sealing surfaces and groove
of rubber profile.
Damaged Recondition
Replace
Check suction basket for damage. Damaged Replace
Check threaded bores for ease of
movement.
Check plug-in pipe, connecting
piece and cover for damage.
Damaged Recondition
Replace
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9.1.20 Oil pan Installation
Special tools
Eyebolt T80092075 4
Material
Engine oil
Express dry cleaner (Loctite 7061) 50518 1
Silicone rubber (Loctite 5970) 50773 1
Spare parts
Rubber profile
WARNING
Heavy object.
Risk of crushing!
WARNING
Heavy object.
Risk of crushing!
Installing suction basket
Note: Minimize contamination!
2. Insert O-rings into groove as shown in overview drawing ( Page 1045).
3. Install suction basket with screws.
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Preparing oil pan for installation
1. Clean flange surfaces of oil pan, equipment
carrier and crankcase.
Note: Use a new rubber profile every time the oil
pan is installed.
2. Place rubber profile in the groove on the oil pan.
3. Coat the rubber profile with grease on the end
face of the free end (arrows).
4. Fit flanges for plug screws at both end faces.
5. Apply surface sealant to fornt cover.
6. Spray lint-free rag with express dry cleaner and
wipe off excess surface sealant on the exposed
flange faces.
7. Coat slit between equipment carrier/crankcase
with silicone rubber on both sides of the equipment
carrier (arrow), laying down a bead of approx.
5 mm.
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8. Coat slit (arrow) between strip/crankcase with
silicone rubber, laying down a bead of approx.
5 mm.
9. Screw eyebolts into bores for plugs on the oil pan.
10. Lift oil pan with lifting ropes and crane.
11. Lower oil pan onto contact surface of crankcase.
12. Align oil pan to bores in the contact surface
of crankcase.
Note: Washers for screw connections A, B and
C are different.
14. Use torque wrench to tighten oil pan screws
to the specified torque according to tightening
sequence ( Page 1053).
14.1. Screw A
14.2. Screw "B
14.3. Screw "C
15. Install flanges with new gaskets.
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9.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG)
Number of cylinders Screw joint Number of screws Item
12V to 20V B (driving end side) 8
-
12V to 20V C (free end side) 10
-
Bolt oil pan to crankcase and equipment carrier alternately and in several steps.
Threaded connections for oil pan made of nodular cast iron (GGG)
A Screw
B Screw
C Screw
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9.1.22 Engine lifting equipment - Overview
Overview
1 Lifting eye 2 Cylinder head screw
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Engine lifting equipment
1 Lifting eye 2 Thrust washer 3 Cylinder head screw
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9.1.23 Engine lifting equipment Removal
Preconditions
Engine lifting equipment Removal
1. Remove cylinder head screws (2).
2. Remove cylinder head screws and thrust
washers (1).
3. Remove lifting eye (3).
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9.1.24 Engine lifting equipment Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Engine lifting equipment Cleaning
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9.1.25 Engine lifting equipment Check
Material
Spare parts
Lifting eyebolt
Thrust washer
Cylinder head screw
Engine lifting equipment Check
Item Findings Task
Check engine lifting equipment for
damage.
Damaged Replace
Check lifting eyebolt with magnetic
Signs of cracks Replace the component with an
original spare part.
Check mating and bolt-on faces for
damage.
oilstone.
Replace
Check threads in crankcase for ease
of movement.
Check cylinder head screws for
damage.
Damaged Replace
Value ( Page 1237)
exceeded.
Replace
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9.1.26 Engine lifting equipment Installation
Special tools
Check engine lifting equipment ( Page 1058)
Installing engine lifting equipment
1. Place lifting eye (3) on cylinder head and align to
the bores for the cylinder head screws.
Note: If only cylinder head screws at lifting eye
were undone just tighten these two cylinder
head screws to specified tightening torque.
2. Screw in cylinder head screw (2) with thrust
washer (1) and use torque wrench to tighten to
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9.1.27 End housing, driving end Overview
End housing with attachments
1 Flywheel housing
2 Deadcenter indicator
3 Hex screw
4 Plug screw
5 Sealing ring
6 Sealing ring
7 Adapter union
8 Hex screw
9 Hex screw
11 O-ring
12 Guard plate
13 Guard plate
14 Hex screw
15 Washer
16 Guard plate
17 Hex screw
18 Guard plate
19 Hex screw
20 Hex screw
21 Spacer bushing
22 O-ring
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Configuration of guide bush for end housing installation and removal
1 Support
2 Guide bush
3 Guide
4 Washer
5 Nut
6 Socket-head screw
7 Flange
8 Flange
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9.1.28 End housing, driving end Removal
Preconditions
Special tools
Bracket T80091102 1
Support F6555724 1
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
End housing Removal
Note: The TOP mark (arrow) on the front of the
guide bushing must face up, regardless of
whether the crankcase is in the installation
position or is turned through 180 .
1. Install support (2) on guide bushing (3)
( Page 1060).
2. Screw bracket (1) on to end housing and attach to
crane using a slightly tensioned rope.
3. Remove all screws for end housing on crankcase
( Page 1060).
4. Remove end housing from crankcase horizontally.
5. Remove O-rings.
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9.1.29 End housing, driving end Disassembly
Special tools
Removal tool for main bearing, driving end F6557190 1
Lukas cylinder B80096717 1
WARNING
WARNING
Heavy object.
Risk of crushing!
Remove end housing, driving end ( Page 1062).
Removing main bearing from end housing
1. Cut axial groove in crankshaft bearing, leaving wall
thickness of approx. 1 mm to relieve tension in
bearing.
2. Fit special tool (1), (2) on end housing.
3. Use special tool to press bearing out of end
housing.
4. Remove remaining parts as per overview drawing
( Page 1060).
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9.1.30 End housing, driving end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
End housing, driving end Cleaning
2. Thoroughly blow end housing, driving end, and all threads clear with compressed air.
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9.1.31 End housing, driving end Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Retainer 0015890321/00 1
Material
Spare parts
Crankshaft bearing
End housing, driving end
End housing, driving end Check
Item Findings Task
Use the magnetic crack-testing
method to check lifting carrier and
eyebolts for cracks.
Check dead-center indicator for
damage.
Damaged Replace deadcenter indicator.
Check mating and bolt-on faces. Stress marks Smooth with oilstone.
Check threads for damage. Damaged Recut threads.
Check crankshaft bearings for
surface condition and wear *.
Stress marks
Damage
visible
Measure bore in end housing,
driving end. Value ( Page 1066)
Value exceeded Replace end housing.
* Replace crankshaft bearings during "Extended component maintenance".
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1
1
6
0
0
4
9.1.32 End housing KS Tolerances
limit
Basic
size
lower
upper
min.
max.
min.
max.
Flywheel housing
bore
223.000
H6
0 +0.029 1
Bearing outer ,
removed
223.263 0 +0.029
0.234 0.292
Bearing bush
bore,
bearing pressed
in
210.142 0 +0.069 2
Hub outer 210.000
g7
-0.061 -0.015
0.157 0.272
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9.1.33 End housing, driving end Assembly
Special tools
Installation tool F30378426 1
Material
Liquid nitrogen
DANGER
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
Check end housing, driving end ( Page 1065).
Installing main bearing in end housing
1. Place end housing on suitable surface to allow
installation of the main bearing in the correct
position.
2. Install stop (1) on rear side of end housing (2).
3. Secure stop (1) on front side of end housing
(2) using two nuts.
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4. Insert main bearing (3) in locating device (5).
5. Insert main bearing (3) and installation tool (2),
ensuring they are correctly positioned with regard
to each other (position mark/notch mark) (4).
6. Press down pins (1) and lock main bearing by
turning.
7. Chill main bearing (3) with insertion tool (2) in
liquid nitrogen.
8. Place main bearing with insertion tool (2) at end
housing (1) in 12 oclock position (arrowed).
9. Insert chilled main bearing with insertion tool (2)
up to stop in end housing (1).
10. After a brief dwell period, unlock and remove
insertion tool (2).
11. Remove stop from rear side of end housing.
12. Install support bracket on end housing.
13. Install remaining parts as per overview drawing
( Page 1060).
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9.1.34 End housing, driving end Installation
Special tools
Support F6555724 1
Material
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
Assemble end housing, driving end ( Page 1067).
Installing end housing, driving end
1. Using fast cleaner 7061, clean mating face
(arrowed) between end housing and crankcase.
2. Apply a uniform coating of surface sealant 518 to
the sealing surface (arrowed) and smooth.
3. Coat O-rings (1) with petroleum jelly and insert
into bores.
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Note: The illustration shows the engine rotated
through 180, i.e. the oil pan mating face
faces upwards.
4. Using fast cleaner 7061 clean mating face
(arrowed) on crankcase (1).
5. Screw guide sleeve (2) onto crankshaft end flange.
6. Install support bracket (1).
7. Position support (2) on end housing.
8. Using support bracket (1), attach end housing
to crane.
9. Position end housing on guide sleeve (3) and push
towards crankcase as far as it will go.
10. Install screws into bores, tightening them to
approx. 10 Nm.
11. Tighten two opposite screws in the inner circle of
the end housing to specified tightening torque
( Page 980).
12. Remove support (2) from end housing and install
screws. Note that the screws have different
lengths.
13. Install all screws and washers and tighten to
specified tightening torque ( Page 980). Observe
the following tightening sequence:
13.1. First tighten the screws in the inner circle of
13.2. Then tighten the screws in the outer circle of
14. Remove excess sealant.
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9.1.35 Crankcase ventilation Overview
1 Vent line
2 Vent line
3 O-ring
4 Screw
5 Rubber sleeve
6 Clamp
7 Vent line
8 O-ring
9 Screw
10 Oil separator
11 Clamp
12 Washer
13 Spacer bush
14 Screw
15 Nut
16 Bracket
17 Screw
18 Guide sleeve
19 Rubber sleeve
20 Clamp
21 Pipe
22 Nut
23 Pipe
24 Nut
25 T-piece
26 Rubber sleeve
27 Clamp
28 Pipe
29 Bracket
30 Link
31 Pipe half-clamp
32 Grommet
33 Screw
34 Pipe half-clamp
35 Pipe
36 Adapter union
37 Sealing ring
38 Flange
39 Gasket
40 Screw
41 Bracket
42 Washer
43 Screw
44 Screw
45 Grommet
46 Pipe half-clamp
47 Pipe half-clamp
48 Washer
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1 Oil separator
2 Screw
3 Clamp
4 Vent line
5 O-ring
6 Screw
7 Vent line
8 Rubber sleeve
9 Clamp
10 Vent line
11 Screw
12 Pipe
13 Nut
14 Pipe
15 Nut
16 T-piece
17 Rubber sleeve
18 Clamp
19 Vent line
20 Vent line
21 Bracket
22 Screw
23 Bracket
24 Screw
25 Pipe half-clamp
26 Grommet
27 Screw
28 Adapter union
29 Sealing ring
30 Flange
31 Gasket
32 Screw
33 Oil pipe
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Crankcase ventilation, free end, 12V, 16V
1 Oil separator
2 Bracket
3 Screw
4 Screw
5 Guide sleeve
6 Rubber sleeve
7 Clamp
8 Pipe
9 Screw
10 Clamp
11 Spacer sleeve
12 Washer
13 Spacer sleeve
14 Screw
15 Nut
16 Oil line
17 Nut
18 Oil line
19 Nut
20 Pipe half-clamp
21 Pipe half-clamp
22 Grommet
23 Screw
24 Washer
25 Washer
26 Rubber sleeve
27 Clamp
28 T-piece
29 Oil line
30 Oil line
31 Banjo screw
32 Sealing ring
33 Threaded bush
34 Sealing ring
35 Bracket
36 Spacer sleeve
37 Screw
38 Pipe half-clamp
39 Grommet
40 Screw
41 Blanking cone
42 Nut
43 Pipe half-clamp
44 Grommet
45 Screw
46 Bracket
47 Screw
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9.1.36 Crankcase ventilation Removal
Preconditions
Crankcase ventilation Removal
1. Remove lines and oil separator as per overview drawings ( Page 1071).
3. Protect oil separator from damage. Even minor damage may cause oil separator failure.
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9.1.37 Crankcase ventilation Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Crankcase ventilation Cleaning
Note: Protect rubber and synthetic parts from oil and fuel, rub dry only, never clean with organic cleaning
agents.
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9.1.38 Crankcase ventilation Check
Material
Corrosion inhibitor
Spare parts
Piping
Oil separator
Clamp
Retainer
Guide sleeve
Spacer bush
WARNING
Hot testing liquid.
Clean crankcase ventilation ( Page 1075)
Crankcase ventilation Check
Item Findings Task
damage and wear.
Damaged Replace
oilstone
Replace
Replace
Pressure-test piping for leaks with
air and corrosion inhibitor in water
bath.
Water temperature min. 30 C,
max. 40 C
Leaking Recondition
Replace
Inspect piping visually. Mechanical damage
Chafing
Indentation
Replace
Check operation of oil separator. Malfunction Replace
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9.1.39 Oil separator Disassembly
Remove oil separator ( Page 1074).
Oil separator variant A Disassembly
1. Undo band clamp (1).
3. Remove filter element (2).
5. Remove O-ring (arrow) from lower part.
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Hengst oil separator variant B Disassembly
1. Remove securing screws (2) for cover (1) with
screwdriver (Torx 30).
3. Remove aerosol element (1) from oil separator
housing (2).
4. Remove securing screws for cover (1).
5. Remove cover (1), spring (2) and O-ring.
6. Remove diaphragm (3) from oil separator housing.
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9.1.40 Oil separator Check
Spare parts
Oil separator
Clean oil separator ( Page 1075).
Oil separator variant A Check
Item Findings Task
damage and wear.
Damaged Replace
oilstone
Replace
Hengst oil separator variant B Check
Item Findings Task
damage and wear.
Damaged Replace
oilstone
Replace
Replace
Pressure-test oil separator for leaks
with air in water bath.
Leaking Replace
Oil separator pressure control can only be checked when installed with engine in operation. Vacuum or
overpressure is measured (e.g. with water pressure gauge) over entire engine speed range. Values should lie
between minus 10 mbar and plus 10 mbar (100 mm water column).
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9.1.41 Oil separator Assembly
Material
Spare parts
Filter element with O-ring
O-rings
Check oil separator ( Page 1079).
Oil separator variant A Assembly
1. Coat O-ring (3) with petroleum jelly and insert in oil
separator housing.
2. Insert filter element (2).
groove provided on oil separator housing.
4. Fit cover (4).
5. Tighten band clamp (1).
6. Insert O-ring (arrow) in lower part.
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Hengst oil separator variant B Assembly
1. Coat O-ring (arrow) with petroleum jelly and insert
in groove provided on oil separator housing (3).
2. Insert diaphragm (2) in oil separator housing (3)
ensuring it is correctly positioned (curvature
facing up).
3. Fit spring (1) on diaphragm (2), ensuring spring (1)
is correctly seated at diaphragm (2).
4. Mount cover (1) on spring (2) in correct position.
5. Insert screws with screwdriver and tighten
diagonally and evenly to specified torque
( Page 980) .
groove (arrow) provided on oil separator housing
(2).
7. Insert aerosol element (1) in oil separator
housing (2), ensuring it is correctly positioned.
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8. Mount cover (1) on oil separator housing and insert
screws (2) with screwdriver and tighten diagonally
and evenly to specified torque ( Page 980) .
9. Check oil separator for leaks ( Page 1079).
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9.1.42 Crankcase ventilation Installation
Material
Spare parts
Gasket
O-ring
Rubber sleeve
Clamp
Crankcase ventilation Installation
3. Install crankcase ventilation as per overview drawing ( Page 1071).
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9.2 Gear Train
9.2.1 Gearcase, free end Overview
1 Equipment carrier
2 O-ring
3 Screw
4 Sealing ring
5 Plug screw
7 Idler gear, right side
8 Idler gear, left side
9 Washer
10 Washer
11 Stud
12 Nut
13 Cover
14 Gasket
15 Stud
16 Oil pump
17 Threaded bush
18 Sealing ring
19 Plug screw
20 Screw
21 Sealing ring
22 Plug screw
23 Pipe clamp half/halves
24 Oil line
25 Gasket
26 Cover
27 Grommet
28 Pressure reduction valve
29 Sealing ring(s)
30 Banjo screw
31 Seal carrier (free end)
33 Axle, intermediate gear
34 O-ring
35 O-ring
36 Drain plug
37 O-ring
38 Gasket
39 Cover
40 O-ring
41 Plug screw
42 Sealing ring
43 Bearing bush
44 Sealing ring
45 Plug screw
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Arrangement of alignment tool for equipment carrier and equipment carrier cover
1 Equipment carrier
2 Alignment tool
3 TOP/OBEN mark
4 Screw
5 Guide bush
6 Screw
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9.2.2 Gearcase, free end Removal
Preconditions
Special tools
DANGER
Suspended load.
Danger to life!
Gearcase Removal
1. Insert two eyebolts (arrows) in gearcase.
2. Use rope to hook gearcase on to crane with
light initial load.
3. Unscrew screws (1) and (2) and remove with
sealing rings.
4. Unscrew and remove screws through bores in
idlers. If screws are not visible, turn crankshaft
accordingly.
5. Mark all screws on gearcase circumference
(arrows). Note that screws differ in length.
6. Remove all screws.
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7. Loosen nuts (2) on left and right sides of crankcase
and remove with washers.
8. Carefully force gearcase (1) with rope slightly
pretensioned towards free end until it is released
from crankcase.
9. Remove O-rings.
10. Set gearcase down and protect from damage.
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9.2.3 Gearcase, free end Disassembly
Special tools
Adapter B80146411 1
Lucas cylinder B80096717 1
Press-out tool F6557191 1
WARNING
WARNING
Heavy object.
Risk of crushing!
Removing crankshaft bearing from equipment carrier
1. Replace crankshaft bearing if damaged or during extended component maintenance.
2. Using press-out tool, Lukas cylinder and hand pump, force crankshaft bearing out of equipment carrier.
Removing radial-lip shaft seal from seal carrier (if fitted)
1. Place seal carrier on a suitable surface.
2. Use suitable extractor to pull out radial-lip shaft seal.
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9.2.4 Equipment carrier free end Cleaning
Material
WARNING
WARNING
Compressed air.
Risk of injury!
CAUTION
Cleaning equipment carrier, free end
1. Clean elastomer parts with cleaner (Hakupur 312).
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9.2.5 Gearcase, free end Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Material
Spare parts
Equipment carrier
Crankshaft bearing
WARNING
Heavy object.
Risk of crushing!
Gearcase, free end Check
Item Findings Task
to check gearcase for cracks.
Signs of cracks Replace gearcase.
Check crankshaft bearings for wear,
scoring and indentation.
Scores
Indentations
Visible
( Page 1088)
Check threads in gearcase for ease
of movement.
Sluggish Recut threads
Check thread and shaft of hex bolts
and studs for damage.
Damaged Replace.
and fits.
Damaged Recondition with oilstone or
emery cloth.
Replace
Measure crankshaft bearing in
gearcase. Values ( Page 1091)
Values exceeded. Replace crankshaft bearings.
( Page 1088)
Measuring crankcase bearing bore
in gearcase. Values ( Page 1091)
Values exceeded. Replace gearcase.
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9.2.6 Gearcase, free end Tolerances
Basic
size
lower
upper
min.
max.
min.
max.
Gearcase bore 193.000
H6
0 +0.029 1
Bearing outer
dia.
removed
193.204 0 +0.029
0.175 0.233 Interfer-
ence min.
0.150
Bearing bush
bore
Bearing press-
fitted
180.121 0 +0.069 2
Driver flange
outer dia.
not press-fitted
179.800
h7
-0.040 0
max.
0.450
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9.2.7 Gearcase, free end Assembly
Special tools
Installation mandrel for radial-lip shaft seal F30377680 1
Material
Denatured ethanol 40250 1
Loctite 7063 50594 1
Liquid nitrogen
Spare parts
Crankshaft bearing
Studs
DANGER
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
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Installing crankshaft bearing in equipment carrier
1. Insert eyebolts in equipment carrier.
with light initial load.
3. Lift equipment carrier and move to installation
position.
4. Place equipment carrier on a firm surface and
secure.
Note: Pay attention to Oben/Top (arrow) mark.
5. Install jig (1).
6. Clean crankshaft bearing with Loctite.
7. Insert crankshaft bearing (1) in locating device (2).
Note: Ensure that position marking on crankshaft
bearing (arrow) and notch mark on
insertion tool are aligned.
8. Insert insertion tool.
9. Lock crankshaft bearing (3) on insertion tool (2)
with tommy bars (1).
10. Chill insertion tool (2) with crankshaft bearing
(3) in liquid nitrogen.
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Note: Location specified is by means of an
asymmetrical pin guide.
11. Use insertion tool (2) to install chilled crankshaft
bearing (1) on inner side of equipment carrier
up to stop.
12. After 60 seconds, unlock and remove insertion
tool (2).
13. Check positions of oil bores on crankshaft bearing.
Installing radial-lip shaft seal in seal carrier (if
applicable)
1. Push radial-lip shaft seal with sealing lip facing
down on to installation mandrel.
2. Clean and degrease sealing face for radial-lip shaft
seal in seal carrier.
3. Coat sealing face of radial-lip oil seal with ethanol.
4. Press-fit radial-lip shaft seal with drift into seal
carrier.
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9.2.8 Gearcase, free end Installation
Special tools
Alignment tool (free end), equipment carrier F6782344 1
Guide bushing for equipment carrier F6557946 1
Eyebolt 0005800100000 1
Material
Spare parts
O-ring
Sealing ring
DANGER
Suspended load.
Danger to life!
DANGER
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
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Installing equipment carrier
1. Install idler gears and axles ( Page 1107).
2. Install delivery valve ( Page 1522).
3. Install pressure reduction valve ( Page 1486).
4. Clean alignment tool (2) and guide bushing and
coat with engine oil.
Note: TOP/BOTTOM marking must face
upwards, independent of the position of
the crankcase.
5. Use screws (1) to install alignment tool (2) on
equipment carrier.
6. Clean tail shaft, free end.
7. Screw guide bushing with screw on to tail shaft.
8. Screw eyebolts (arrows) into equipment carrier.
with light initial tension.
10. Clean contact surface (arrowed) with Loctite 7061,
ensuring that its is free of grease and dry.
11. Coat equipment carrier sealing face with Loctite
518.
12. Coat O-rings (1) with petroleum jelly and insert into
groove on equipment carrier.
Note: Woolen thread instructions do not apply to
disassembly if not fitted.
13. Lead woolen thread (2) past and close to O-ring
grooves (1).
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14. Using crane, move equipment carrier (3) over
crankshaft guide bushing (1). Always note:
14.1. The studs (2) must be aligned.
14.2. Both idler gears and the crankshaft gear
must be aligned with each other.
14.3. In each case, position one of the round
recesses on the idler gears so that screws
can be retightened. If the holes are not
visible, rotate engine accordingly.
15. Screw in nuts and washers and tighten.
Note: Relieve load on crane ropes before
tightening nuts and screws.
16. Tighten screws in the sequence 5, 6, 3, 2, 4 and 1.
17. Insert screws (arrows) evenly and tighten.
18. Remove alignment device and guide bushing.
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19. Insert screws (1) and (2) with new sealing rings.
20. Remove ropes and eyebolts.
21. Install oil line ( Page 1486).
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9.2.9 Gear train, free end Overview
teeth
(mm)
Axial clearance
(mm)
low-temperature circuit
32 0.201 0.065 to gear 9

high-temperature circuit
32 0.201 0.065 to gear 9

3 Crankshaft gear 48

4 Camshaft gear 96 0.286 0.081 to gear 3 0.1 to 0.18
5 Gear, H.P. fuel pump 32 0.201 0.065 to gear 6

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teeth
(mm)
Axial clearance
(mm)
7 Gear, battery-charging generator 19 0.222 0.128 to gear 6

8 Gear, oil pump 34 0.279 0.077 to gear 9

10 Gear, hydrostatic pump 34 0.201 0.065 to gear 9

1 Coolant pump drive gear
2 Shaft
3 Idler gear
4 Crankshaft
5 Crankshaft gear
7 H.P. fuel pump drive gear
9 Drive flange, free end
10 Drive gear
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9.2.10 Gear train, free end Removal
Preconditions
WARNING
Heavy object.
Risk of crushing!
Removing idler gears
1. Place equipment carrier on a clean and flat
surface.
2. Remove screws (1) and (2).
3. Insert jackscrews M8 with continuous thread in
thread (arrows) of axle (3).
4. Press off axle evenly.
Removing axles
1. Mark respective axle according to installation
position and remove from equipment carrier.
2. Remove idler gears from fit.
3. Remove bearing bushing of idler gear
( Page 1110).
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9.2.11 Gear train, free end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Gear train, free end Cleaning
1. Clean idler gears and oil bores of axles with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Thoroughly clean gear train, free end, by blowing clear with compressed air.
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9.2.12 Gear train, free end Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Material
Spare parts
Idler gears
Axle
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Gear train, free end Check
Item Findings Task
to check idler gears for cracks.
Signs of cracks Replace idler gears.
Check surface quality of idler gear
tooth flanks with magnifying glass.
Damaged Replace idler gear.
Check running surface of axles,
bearing bushes in idler gears and
axial friction faces of gears for wear,
scores and stress marks.
Scores
Stress marks
visible
Replace
Check taper seat and bolt-on
surface of axles for scoring and
stress marks.
Scores
Stress marks
visible
Corrective work
Replace
Check screws for damage and
Damaged
Sluggish
Replace screws
Measure bearing bushing bore in
idler gear. Values ( Page 1105)
Values exceeded Replace bearing bushing bore
( Page 1110).
Use micrometer to measure outer
diameter of axles at running surface.
Values ( Page 1105)
Values exceeded Replace axle.
Measure equipment carrier bore
of idler gear axles. Values
( Page 1105)
Values exceeded Replace equipment carrier.
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9.2.13 Gear train, free end Tolerances
limit
Basic
size
lower
upper
min.
max.
min.
max.
Equipment carrier
bore
81.000
H7
0 +0.035 1
H7
0.035 0
0 0.070 Clear-
ance
max.
0.080
Idler gear bore 80.000
H7
0 +0.030 2
Bush outer dia. 80.000
s6
+0.059 0.078
0.029 0.078
Cylinder liner ID
installed 75.000
H8
0 +0.046
removed 75.000
E6
+0.060 +0.079
3
e7
0.090 0.060
0.060 0.136
Equipment carrier
bore
75.000
P7
0.051 0.021 4
e7
0.090 0.060
0.009 0.069 Clear-
ance
max.
0.080
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limit
Basic
size
lower
upper
min.
max.
min.
max.
Equipment carrier
width
41.200 0 0.200
Idler gear width 40.700 0.100 0
0.500 0.800 Clear-
ance
max.
0.900
5
Measure equipment carrier width unclamped.
6 Crankcase
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9.2.14 Gear train, free end Installation
Special tools
Holder 0015890321/00 1
Material
Engine oil
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
Check gear train, free end ( Page 1103).
Installing idler gear in equipment carrier
1. Coat bearing bushings in idler gear with engine oil.
2. Insert idler gear (2) through opening (arrow) into
equipment carrier (1), ensuring it is correctly
positioned.
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Installing axles
1. Ensure oil bores of axle (3) are perfectly clean.
2. Coat O-ring (1) and (2) with petroleum jelly.
3. Insert O-ring (2) into groove of equipment carrier
(4).
4. Fit O-ring (1) in groove in axle base.
5. Insert axles into equipment carrier. Pay attention
to fit of idler gear.
6. Press axle (3) into equipment carrier.
7. Install hex screws (1) and tighten evenly.
8. Screw in screw (2).
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Checking axial clearance and backlash
1. Install two eyebolts in equipment carrier.
2. Attach equipment carrier to crane with ropes and
tension ropes equally.
3. Position equipment carrier vertically.
4. Mount magnetic dial-gauge holder (3) with dial
gauge (2) in equipment carrier.
5. Measure axial clearance:
5.1. Place dial gauge stylus with preload on
lateral collar of idler gear (1).
5.3. Check axial play by moving idler gear back
and forth in axial direction. Axial clearance
limit values ( Page 1099).
6. Measure backlash:
6.1. Position dial gauge stylus with preload on
a tooth flank of idler gear.
6.3. Move idler gear back and forth in radial
direction to check backlash.
6.4. Compare with specified values in table
( Page 1099).
7. If limit values are exceeded, replace idler gears.
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9.2.15 Bearing bushing of idler gear Removal and installation
Material
Liquid nitrogen
Spare parts
Bushing
DANGER
WARNING
Component is hot.
Risk of burning!
Bearing bushing Removal
1. Clean idler gear ( Page 1102)
2. Using a suitable sleeve and manual press, remove
bearing bushing (1) from idler gear (2).
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Bearing bushing Installation
1. Measure main bore (3) in idler gear (2). Values
( Page 1105)
2. Place idler gear on a suitable surface. Ensure that,
when inserting the bearing bushing (1), there is
no lateral projection.
3. Cool bearing bushing in liquid nitrogen and heat
idler gear to 80 C.
4. Insert chilled bearing bushing in idler gear.
Observe distance (A) 0.35 mm 0.15 mm.
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9.3 Crank Drive
9.3.1 Running gear Overview
Running gear
1 Flywheel
2 Ring gear
3 Piston
4 Conrod
5 Crankshaft
6 Crankshaft gear, free end
7 Vibration damper
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9.3.2 Crankshaft Overview
Crankshaft detail
1 Vibration damper
2 Crankshaft bearing, free end
4 Piston
5 Cylinder liner
6 O-ring
7 Oil spray nozzle
8 Conrod
9 Crankcase
10 Conrod screw
12 Socket-head screw
13 Stud *
14 Nuts, crankshaft bearing cap
15 Crankshaft bearing cap
16 Crankshaft gear
17 O-ring
18 Crankshaft
19 O-ring
20 Hex screw
21 Seal carrier
22 Drive flange
* New studs must be pretensioned prior to first tightening
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Crankshaft
1 Crankshaft
2 Counterweight
3 Stress bolt
4 Plug
5 Crankshaft gear
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Crankshaft with bearings
1 Crankshaft bearing, top
2 Crankshaft bearing, bottom
3 Upper alignment bearing
4 Lower alignment bearing
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9.3.3 Crankshaft Removal
Preconditions
Special tools
Crankshaft locating device F6553644 2
Removal tool for crankshaft bearing caps F6783568 1
DANGER
Suspended load.
Danger to life!
WARNING
Risk of injury!
1. Check marking (1) of the crankshaft bearing caps
in relation to the crankcase.
2. If there is no marking (1): starting at driving
end, emboss main bearing numbers making
sure they can be read from the same direction.
Height of numeral punch: 6 mm.
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3. Turn crankcase upside down in swivel frame with
oil pan mating horizontal and facing upwards.
4. Remove socket-head screws (arrows) and remove
strip (1) from crankcase (2).
5. Remove all lateral screws for crankshaft bearing
caps from crankcase.
6. Starting at 1st bearing cap (driving end), position
hydraulic pretensioner on bearing cap studs.
7. Insert hydraulic screw pretensioner by hand.
8. Connect high-pressure hoses (1) of hydraulic
pump to hydraulic pretensioner (2).
9. Position magnetic holder and dial gauges on
crankcase mating face.
10. Center both gauge tips on the measuring points.
12. Operate hydraulic pump and simultaneously
elongate studs by a max. 0.25 mm.
13. Use a pin to loosen crankshaft bearing cap nut.
14. Release studs.
15. Position magnetic holder, dial gauges and
hydraulic pretensioner on next bearing cap.
16. Loosen and remove all nuts in the same sequence.
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1. Use removal tool to remove crankshaft bearing caps.
2. Remove bearing shell from crankshaft bearing cap and mark.
Crankshaft Removal
1. To protect the crankshaft, fit sliding protection
sleeves over studs of first and last bearings.
2. Using rope (1) and crane, lift crankshaft (2) clear
of crankcase.
3. Ensure horizontal positioning of the crankshaft
when lifting.
4. Lower crankshaft on to firm supports.
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5. Use removal jig to remove bearing shells from
bearing pedestals.
6. Mark bearing shells that point towards the driving
end with the number of the corresponding main
bearing (arrow).
7. The marking (arrow) must be made by etching or
with a permanent marker.
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9.3.4 Crankshaft Disassembly
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
Removing counterweights
Note: If counterweights are to be removed, mark
relevant counterweight in its installation
position on the crankshaft prior to removal.
1. Determine and record distance A (web to
counterweight).
2. Check that counterweights are consecutively
numbered.
3. If the numbering is not visible, punch in new
numbers.
4. Lower crankshaft onto firm assembly frame.
5. Remove screws (2) and counterweight (1).
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9.3.5 Crankshaft - Cleaning
Preconditions
Material
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
Heavy object.
WARNING
CAUTION
Crankshaft - Cleaning
2. Clean crankshaft and all threads with compressed air.
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9.3.6 Crankshaft Check
Special tools
DynaMIC hardness tester Y20506341 1
Retainer 0015890321/00 1
Bore gauge, 100-160 mm Y20091482 1
Material
Spare parts
Crankshaft
Counterweight
Screw
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
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Crankshaft Check
Item Findings Task
Check mating faces of
counterweights for wear.
Wear visible Smooth with oilstone.
Use micrometer to measure
diameter and roundness of main
bearing journals and crankpins.
Record measured values in data
sheet. Values ( Page 1126)
Values fallen short of. Corrective work: To be carried out
only in workshops authorized by
MTU.
Check crankshaft counterweight
with magnetic crack-testing method
for cracks.
Signs of cracks Replace crankshaft counterweight
( Page 1120).
Check crankshaft gear for stress
marks.
Stress marks visible Corrective work
Replace: To be carried out only
in workshops authorized by
MTU.
Using engineers blue, check that
screw heads fit correctly.
Unevenly fitted. Level mating face.
Measure shaft length of screws with
depth gauge. Permissible shaft
length ( Page 980)
Dimension exceeded Replace screw.
with fluorescent magnetic powder to
check screws for cracks.
Signs of cracks Replace screw.
Make sure that threads are in perfect
condition.
Sluggish
Damaged
Replace screw.
Checking crankshaft for cracks
1. Install crankshaft in longitudinal direction between
jaws of test device.
2. The specified magnetic field strength of 20 A/cm
to 60 A/cm must be applied at every part of
the component.
3. Use magnetic crack-testing method to check
crankshaft for longitudinal and transverse cracks.
Also check the oil and journal bores as well as the
mating faces on counterweights and threaded
bores.
Result: If there are signs of cracks, replace
crankshaft.
4. After crack-testing, demagnetize crankshaft. A
residual field strength of 2.5 A/cm to 4 A/cm
must not be exceeded.
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Checking crankshaft journal and taper
1. Check taper surfaces (arrows) for scoring and
damage.
2. Remove minor scoring and damage by polishing
with emery cloth.
3. Recondition taper: To be carried out only in
Checking hardness of journals
Note: Check hardness of all journals when
not installed.
1. Check hardness of all journals using the DynaMIC
tester or other suitable hardness tester. Required
hardness: 49 HRC to 53 HRC.
Result: If values are fallen short of, contact
Service.
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Checking concentricity of crankshaft
1. Place crankshaft on rollers in main journals on main bearing.
2. Use adjustable measuring holder and dial gauge to check bearing journals for concentricity.
3. If wear on circumference of journal is irregular, measure at transition from cylindrical section of journal to
radius. Values ( Page 1126).
Result: If measured values deviate: Recondition crankshaft only in workshops authorized by MTU.
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9.3.7 Crankshaft Tolerances
Crankshaft bearing
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
0 171.000 H6 171.035
Trans-
verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
ovality
max. 0.050
1 Crankcase bore
for crankshaft
bearing
2 172.000 H6
0 +0.025
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Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
0 - 0 160.120
0 - 1 159.620
0 - 2 159.120
0 - 3 158.620
1 - 0 160.120
1 - 1 159.620
1 - 2 159.120
Alignment and
crankshaft
bearing
installed
1 - 3 158.620
0 +0.054 Trans-
verse
ovality
max. 0.050
0 - 0 160.000 h6 159.970
0 - 1 159.500 h6 159.470
0 - 2 159.000 h6 158.970
0 - 3 158.500 h6 158.470
1 - 0 160.000 h6 159.970
1 - 1 159.500 h6 159.470
1 - 2 159.000 h6 158.970
2
Main bearing
1 - 3 158.500 h6
0.025 0
0.120 0.199
158.470
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Conrod bearings
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
H6
0 +0.025
0 - 0 117.082
0 - 1 116.882
0 - 2 116.682
Conrod bearing
bore
Conrod bearing
installed
0 - 3 116.482
0 +0.048
0 - 0 117.000 h6
0 - 1 116.800 h6
0 - 2 116.600 h6
2
Conrod journal
0 - 3 116.400 h6
0.022 0
0.082 0.152
Crankpin length 97.500 0.100 +0.100 3
0.200 0.600
0 - 0 126.400
0 - 1 126.400
0 - 2 126.400
4 Expanding
dimension
Conrod bearing
shell, upper and
lower part
0 - 3 126.400
0 +1.000
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Crankshaft bearing, alignment bearing expanding dimension
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Guide bearing, upper half
2 Guide bearing, lower half
0 - 0 171.200
0 - 1 171.200
0 - 2 171.200
0 - 3 171.200
0 +0.500
1 - 0 171.700
1 - 1 171.700
1 - 2 171.700
3 Expanding
dimension
Guide bearing,
upper and lower
part
1 - 3 171.700
0 +0.500
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Crankshaft bearing expanding dimension
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Crankshaft bearing, upper half
2 Crankshaft bearing, lower half
0 - 0 171.400
0 - 1 171.400
0 - 2 171.400
0 - 3 171.400
0 +1.000
1 - 0 171.900
1 - 1 171.900
1 - 2 171.900
3 Expanding
dimension
Crankshaft
bearing, upper
and lower part
1 - 3 171.900
0 +1.000
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Crankshaft axial play
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Crankshaft axial
play
0.200 0.600 Clear-
ance
min. 0.100
max. 0.700
2 Drive flange,
pressed on
156.000 0.010 +0.010
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Bearing shells installed and bearing caps tightened as per specification.
Measure crankshaft bearing bores:
Determine diameters a, b1 and b2 in the measuring planes 1 and 2 and calculate
the average values for a, b1 and b2.
Check roundness of crankshaft bearing bores.
b2 in the formula: (b1+b2) /2 a
Replace bearing shells if:
roundness deviation >0.040
b1 : b2 is above/below 0.040
vertical ovality a > (b1+b2) /2
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Crankshaft gear, free end
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
1 Gear, pressed on
Crankshaft front
end to gear front
end
145.500 0.300 +0.300
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Main bearing journal concentricity
Crankshaft (8V)
Crankshaft (12V)
Crankshaft (16V)
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Crankshaft (20V)
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9.3.8 Crankshaft - Assembly
Special tools
Spare parts
Crankshaft gear
End cover
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
Check crankshaft ( Page 1122).
Installing counterweights
1. Measure shaft lengths of counterweight screws.
Max. shaft length ( Page 980).
2. Smooth mating surface for counterweight with
oilstone.
3. The mating faces of crankshaft and counterweight
(2) must be dry and free of grease.
4. Coat threads and screw head mating face of
screws (1) with engine oil.
5. Position counterweight on crankshaft according to
markings and slightly tighten screws.
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6. Align counterweight to marking (A) and tighten
screws to specified pretightening torque
( Page 980).
7. Check that the installation position of the
counterweight matches the markings or measured
dimensions made before installation.
8. Mark screw heads.
9. Tighten screws to specified additional angle of
rotation.
10. After installing counterweights, check identification
marks on counterweights and webs.
11. Dynamically balance crankshaft. ( Page 1138).
12. Starting from driving end, mark counterweights
with number punch.
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9.3.9 Crankshaft Balancing
Special tools
Master weights
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Preparatory steps
1. Prior to balancing, seal all oil bores.
2. Support crankshaft at shaft journals.
3. Depending on stroke position (free residual moment), master weights must be used for dynamic balancing to
simulate the rotating and oscillating mass of conrod and piston.
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Dynamic balancing
Crankshaft (8V) Crankshaft (12V) Crankshaft (16V) Crankshaft (20V)
Maximum operating
speed
2100 rpm 1900 rpm 2100 rpm 1900 rpm
Support crankshaft
at shaft journals
1 and 5 2 and 6 2 and 8 2 and 10
Balancing assembly
mass
463 kg 525 kg 775 kg 842 kg
Balancing speed 150 rpm 150 rpm 150 rpm 150 rpm
unbalance per
compensation level
for initial balancing
135 gcm 160 gcm 200 gcm 240 gcm
unbalance per
compensation level
in other clamp or
balancing machine
(comparison)
400 gcm 480 gcm 600 gcm 720 gcm
Minimum wall
thickness around
bore
5 mm 5 mm 5 mm 5 mm
A 5 (min.)
B 10
C 32 (min.)
D 8V, 12V, 16V: 18 mm (max. bore diameter); 20V:
20 mm (max. bore diameter)
E 40 mm (max. bore depth)
Bore values at counterweights
1. To balance crankshaft remove material from
counterweights by drilling with twist drill.
2. After balancing, recheck numbers on
counterweights and renumber if necessary.
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9.3.10 Crankshaft bearing shells - Check
Remove crankshaft ( Page 1116).
Crankshaft bearing shells - Check
Item Findings Task
In the case of reuse (e.g.
non-scheduled removal), check
bearing shells for surface wear,
scores, cracks, corrosion, erosion
and damage.
Wear, scores, cracks, corrosion,
erosion or damage visible
Replace
Check bearing shell butt and bearing
rear side for damage and fretting
corrosion (pitting).
Fretting corrosion visible Replace and determine cause.
Possible causes:
Insufficient screw pretension
Assembly error
Spread dimension of bearing
shell out of tolerance
Faulty bearing support bore
Measure spread dimension.
( Page 1126).
Determined value exceeded Replace bearing shell.
Main bearing shells (grooved bearing), upper half
Running surface has following properties when new:
A approx. 75% slide layer
B approx. 25% intermediate layer
C 5% sputtered blocking layer
Assessment
Wear of the bearing running surfaces starts at the galvanized slide layer (a). In the event of further wear, the
difference between the intermediate layer (b) and slide layer (a) remains almost constant.
A magnifying glass is required for a more accurate assessment of the running surface
wear condition (magnification min. 5x).
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In doing so, the slide layer is visible as a dark zone and the intermediate layer as a light zone. The
following is decisive for the wear condition of the grooved bearing:
Width of intermediate layer
Width of groove
Expansion of worn surface
The grooved bearing is still functional if the slide layer is partially missing in the grooves.
During each assessment of the condition of the grooves, the running surface in the area subject to
least load (groove mostly new) should be used for comparison.
The condition of the grooved bearings is assessed in five groups:
1. Continued use
2. Wear
3. Borderline wear and levelling
4. Slide layer fatigue fractures
5. Borderline slide layer continuous fractures and empty grooves
Main bearing shell (sputtered bearing), lower half
1 Slide layer
2 Blocking layer
3 Intermediate layer
4 Protective steel shell
Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the blocking layer areas exposed.
Wear of the bearing running surfaces starts at the galvanized slide layer (1).
The use of the bearing shell is already restricted in friction area once the slide layer is reduced to 70%!
It is often difficult to differentiate between the nickel barrier and softer slide layer.
If in doubt, consult a bearing specialist.
Renew bearing shells at extended component maintenance.
Damage to bearing
Damage to bearings occurs mainly through foreign body scoring, impressions and embedding,
cavitation and corrosion, pitting, fatigue and installation faults.
Bearings showing such damage must be replaced.
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9.3.11 Crankshaft bearing bore Check
Special tools
Bore gauge, 100-160 mm Y20091482 1
Installation/removal device F6553647 1
Retainer 0015890321/00 1
Material
Engine oil
Spare parts
WARNING
Compressed air.
Risk of injury!
WARNING
Risk of injury!
Note: The crankshaft bearing bore must first be checked without and subsequently with main bearings installed.
Measure crankshaft bearing bore with main bearings installed
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Measuring bearing shells
3. Check codes for repair size and journal diameter
of new shells and bearing number of used
shells. These markings must be on sides facing
the driving end.
4. Compare crankcase data sheet and crankshaft
data sheet.
5. Manually press bearing shells on crankcase side
into crankcase bore to form a positive connection.
Ensure that oil bores (arrows) in bearing shells and
6. Insert bearing shells in crankshaft bearing caps
according to markings or bearing number.
7. Position bearing shell so that bearing numbers are
aligned and facing driving end.
8. Position installation tool (1) between bearing
cap stud and rear face of shell on side where
open joint is.
9. Press bearing shell on cap side (2) against guide
bearing shell on crankcase side. Make sure that
the shell joint is closed.
10. Align bearing shells axially.
12. Adjust bore gauge with adjusting ring or
micrometer to reference size of bearing bore.
13. Coat running surfaces of crankshaft bearing
shells with engine oil.
14. Measure crankshaft bearing bore ID with bore
gauge.
16. Compare measured values with specifications
( Page 1126).
17. If values are exceeded, recondition bearing shells
to next repair size or replace.
18. After measuring crankshaft bearing bores, if
necessary mark bearing shells according to
bearing point number.
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Checking crankshaft bearing bore without main bearing installed
2. Remove bearing shells. Protect against damage.
4. Measure crankshaft bearing bore in same way as with installed bearing shells.
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9.3.12 Crankshaft Installation
Special tools
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
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Installing bearing shells
Note: Top and bottom bearing shells have
different part numbers. First crankshaft
bearing on driving end is designed as an
alignment bearing.
3. Use installation/removal tool to manually insert
the bearing shells on the crankcase side in
accordance with bearing numbers in crankcase
bore to form a positive connection.
4. Check stage of main crankshaft bearing bore and
stage of bearing shells. For data, see crankcase
data sheet and crankshaft data sheet.
5. Align alignment bearing shell and remaining
bearing shells with press-in tool in crankcase
bores.
Crankshaft Installation
1. Wipe bearing surfaces on crankshaft with chamois
leather.
2. Spray running faces of bearing shells on crankcase
side with engine oil.
3. To protect crankshaft, slide locating device (1)
over studs of first bearing (2).
4. Slide protective sleeve (2) over studs on last
bearing.
5. Lift crankshaft using rope slings (1) and crane.
6. Align crankshaft horizontally and vertically with
line of bores in crankcase and gradually lower
crankshaft.
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7. Remove protective sleeves and locating device.
Note: Do not rotate the crankshaft until the axial
alignment bearing has been installed.
8. Wipe lower bearing shell and crankshaft bearing
cap with chamois leather, spray running surface
with engine oil and install.
9. Check alignment of upper and lower bearing
shells. Bearing numbers on shells must be aligned
and all numbers must face driving end.
10. Position installation tool (1) between bearing cap
stud and rear face of shell on side where joint is.
11. Compress bearing shell on cap side and press
against shell on crankcase side.
Result: The joint between the shells must be
closed.
12. Axially align bearing shells.
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Note: Crankshaft bearing caps must not be
interchanged!
2. Assign bearing cap to respective bearing
according to crankcase marking (1). If not present,
stamp numbers of main bearing (1), starting
at driving end.
3. Carefully position assigned bearing cap on
respective bearing.
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4. Tap crankshaft bearing cap lightly to move to
final position.
5. Coat threads and mating faces of studs (1) with
engine oil.
6. Turn bearing cap nuts to mating face of bearing
caps.
7. Starting with 1st bearing cap (driving end or free
end), fit support sleeve (2) of hydraulic screw
pretensioner on studs (1) of respective crankshaft
bearing cap.
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8. Turn hydraulic screw pretensioner (1) by hand
until it is in position.
9. Connect high-pressure hose of hydraulic hand
pump to hydraulic screw pretensioner.
10. Position magnetic holder with dial gauges on
crankcase mating face to measure stud elongation.
11. Position the two dial gauge tips centrally on the
respective measuring core (arrow) on the sleeve
measuring pin.
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13. Operate hydraulic hand pump and elongate studs
at the same time (max. 1.15 mm +0.05 mm), use a
pin (arrow) to fit nuts on crankshaft bearing cap.
Note: Residual elongation of studs after release:
0.9 mm +0.05 mm
14. Relieve studs, check elongation of studs.
15. If residual elongation of studs is outside tolerance,
loosen nuts, and repeat nut tightening procedure; if
necessary, replace studs.
16. Mount dial gauges with magnetic holders and
hydraulic screw pretensioner on studs of adjacent
bearing cap and follow the same procedure to fit
all remaining nuts.
17. Coat screws (arrow) with engine oil.
18. Insert screws (arrow) and use torque wrench to
tighten to specified torque ( Page 980).
19. Install strip (driving end) ( Page 1024).
20. In order to avoid damage to the
crankshaft bearings, install locating device (1)
before cranking the crankshaft.
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21. Fit barring tool (2) with screws on crankshaft (1)
(free end).
22. Turn crankshaft with barring tool and check for
ease of movement.
Measuring axial play of crankshaft
Note: Measure axial play only with drive flange or
flywheel mounted.
(1) on crankcase.
2. Position dial gauge tip on face of crankshaft.
3. Use pry bar to press crankshaft axially as far as
it will go.
4. Set preloaded dial gauge to zero.
5. Move crankshaft from stop to stop (arrows) and
enter measured value (axial play) on data sheet.
6. If the determined value is out of tolerance
( Page 1126), remove crankshaft and determine
the cause.
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9.3.13 PTO flange, driving end, flywheel Overview
1 Flywheel
2 Graduated disc
4 Screw
6 Spring pin
7 Dished washer
8 Screw
9 O-ring
10 O-ring
11 Cover
13 Screw
14 Cover
15 O-ring
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Layout for installation/removal jig for flywheel
1 Spacer
2 Screw
3 Adjusting mandrel
4 Connection
5 Flange
6 Pressure sleeve
7 Tension spindle
8 Hydraulic nut
9 Pressure line
10 Support
11 Nut
to 20 mm
C Press-fitted flush
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9.3.14 PTO flange, driving end, flywheel Removal
Special tools
Hand pump set 5555890063/00 1
Trestle T80091387 1
Adapter F6555788 1
Impact extractor F30377999 1
DANGER
Suspended load.
Danger to life!
WARNING
Removing flywheel
1. Remove screws (2) together with washers (3).
2. Remove plug (1) from flywheel.
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4. Install adapter (2) for impact extractor (3) with
screws (5).
5. Remove cover (4) from flywheel (4) with impact
extractor (3).
6. Install installation/removal tool on crankcase
journal, driving end, as shown in overview drawing
( Page 1153).
7. Turn crankshaft, until fixation (1) on spacer (2)
engages in flywheel.
8. Insert tension spindle into crankshaft.
9. Measure check dimension A ( Page 1153).
10. Slide pressure sleeve (2) and hydraulic nut (1) over
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11. Remove screw for expanding bore in flywheel.
nut (3).
15. Fully tighten hydraulic nut (3) to stop, then back off
nut for a distance equal to push-on dimension
( Page 1153).
19. Actuate hydraulic unit (2) and to bring hydraulic
nut at minimum pressure p
2
(start of pressure
increase) to attachment with flywheel.
max
at
flywheel.
21. Actuate hand pump (1) for expanding the flywheel,
until half of the maximum expansion pressure
p
1
is reached.
1
23. Increase expansion pressure gradually in steps of
0,1 x p
max
with hold times of approx. 2 minutes
until the flywheel comes clear off the crankshaft.
Do not exceed maximum expansion pressure p
max
.
pressure.
2
of the flywheel from the taper seat is indicated by
rising pressure p
2
.
26. Gradually drain oil in hydraulic nut, while at the
same time continuing to pump.
27. Relieve pumps (1) and (2).
28. Screw trestle into flywheel and attach flywheel to
crane with rope lightly pretensioned.
29. Remove HP line.
30. Remove nut, support, hydraulic nut and pressure
sleeve.
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32. Lift flywheel through assembly sleeve (arrow)
out of end housing.
33. Place flywheel on a clean surface and secure.
34. Remove nut, assembly sleeve, flange and spacer.
35. Clean assembly surfaces on flywheel and
crankshaft.
36. Close openings using suitable covers.
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9.3.15 Radial-lip shaft seal, driving end Removal
Removing radial-lip shaft seal from end housing
1. Remove end housing, driving end ( Page 1062).
2. Use a suitable extractor to extract radial-lip shaft seal from end housing. Do not damage end housing and
crankshaft.
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9.3.16 Flywheel on PTO flange, driving end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Flywheel on PTO flange, driving end Cleaning
2. Remove cleaner.
3. Thoroughly blow all threads clear with compressed air.
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9.3.17 Flywheel on PTO flange, driving end Check
Material
Spare parts
Flywheel
End cover
Coiled spring pin
WARNING
Heavy object.
Risk of crushing!
Flywheel on PTO flange, driving end Check
Item Findings Task
to check flywheel and ring gear for
cracks.
Signs of cracks Replace.
Check mating faces on flywheel for
evenness, stress marks, scoring
and indentations.
Stress marks
Scores
Indentations
visible
Corrective work
Replace
Check ring gear for wear. Signs of wear Corrective work
Replace
Check end cover for wear. Signs of wear Corrective work
Replace
Measure outer diameter (hub) of
flywheel. Value ( Page 1066)
Value fallen short of. Replace flywheel.
Check thread of expanding bore. Damaged Recut thread.
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9.3.18 Radial-lip shaft seal, driving end Installation
Special tools
Material
Ethanol 40250 1
Spare parts
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
Installing radial-lip shaft seal in end housing,
driving end
Note: Install radial-lip shaft seal only in mounted
end housing, driving end.
1. Install flange with spacer on front face of crankshaft
2. Fit radial-lip shaft seal, with sealing lip facing
outwards, on press-in tool.
3. Coat sealing face of radial-lip shaft seal with
ethanol.
4. Clean and degrease locating bore for radial-lip
shaft seal in end housing, driving end.
5. Position press-in tool and secure with hand screw.
6. Use press-in tool to install radial-lip shaft seal flush
in end housing, driving end.
7. Remove press-in tool with flange from crankshaft.
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9.3.19 PTO flange, driving end, flywheel Installation
Special tools
Hand pump set 5555890063/00 1
Trestle T80091387 1
Material
Engine oil
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
CAUTION
Check flywheel on PTO flange, driving end ( Page 1161).
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Installing timing wheel
1. Attach timing wheel (2) with screws (1) to flywheel,
do not tighten.
2. Drive spring pins (arrow) into flywheel.
Pressing on flywheel
1. Prior to installation, remove all covers.
2. Clean and degrease taper surface on crankshaft
with cleaner and dry and degrease with lint-free
cloth.
3. Coat lip of radial-lip oil seal with petroleum jelly.
4. Screw in tension spindle (1) and measure
reference dimension A of tension spindle
( Page 1153).
5. Install spacer (3) and flange (2) together with
screws on crankshaft face.
7. Use rope to attach flywheel to crane with rope
8. Use crane to insert flywheel through guide sleeve
into end housing,
9. Remove assembly sleeve (arrow).
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10. Calculate push-on distance by measuring distance
from end face of crankshaft to end face of flywheel
with depth gauge.
11. If measured value is smaller than push-on distance
B, check taper for dimensional accuracy.
12. Slide pressure sleeve and hydraulic nut (3) over
nut (3).
19. Prior to press-fitting, moisten tapers fit with
expansion fluid. In doing so, actuate hand
pump (1), until expansion fluid emerges at hub
ends.
20. Actuate hydraulic unit (2) for hydraulic nut, and
attach at installation on flywheel using minimal
pressure.
max
at
flywheel.
22. Pump in expansion fluid until expansion
pressure (p
1
) can no longer be increased (do not
exceed expansion pressure P
max
), then increase
force-on force by increasing force-on pressure (p
2
).
23. Select force-on force so that end position
(pressure bush is seated against flywheel) is
achieved in approx. 5 steps.
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expansion pressure.
26. Unscrew HP lines.
27. Remove nut, support, hydraulic nut, pressure
sleeve and tension spindle after prescribed
soaking time.
28. Coat O-rings (8) with petroleum jelly and insert in
groove on cover (7).
31. Coat O-rings (1) and (3) with petroleum jelly and
insert in groove on plug (2).
33. Coat screws (4) with Loctite 270 and screw in
together with washers (5).
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9.3.20 Crankshaft PTO, Free end Overview
1 Adapter flange
2 O-ring
3 Screw
4 Washer
5 O-ring
6 O-ring
7 Protective cover
8 Screw
9 Washer
10 Screw
11 Sealing ring
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Arrangement of the drive flange installation/removal tool
1 Draw spindle
2 Nut
3 Support
4 Connection
5 Hydraulic nut
6 Pressure sleeve
7 Flange
8 Spacer bushing
9 Drive flange
10 Crankshaft
11 Seal carrier
12 Screw
to 77.05 mm
a Push-on travel: 15.5 mm
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9.3.21 Vibration damper on PTO, free end Removal
Preconditions
Special tools
Installation/removal tool F0140771 1
Material
Engine oil SAE 10 W
DANGER
Suspended load.
Danger to life!
WARNING
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Removing vibration damper
1. Remove protective cover.
2. Block flywheel by securing with positioning fixture
on end housing.
3. Remove screws (2), one screw is left for securing
purposes.
4. Screw in two adjusting mandrels in opposing
threaded bore of drive flange.
5. Remove remaining screws.
6. Insert two jackscrews with continuous thread
in thread (1).
7. Press off vibration damper.
8. Attach vibration damper (1) with lifting gear (3)
and support bracket to crane using a lightly
tensioned rope and remove.
9. Remove adjusting mandrels (2).
Pressing off drive flange
1. Screw draw spindle (4) into crankshaft.
2. Check reference dimension A ( Page 1167).
3. Read off push-on dimension at drive flange (1).
4. Mount installation/removal tool as per overview
5. Screw in connecting piece (2) in drive flange (1).
6. Connect HP line for drive flange expansion to
connecting piece.
7. Insert adapter in connection of hydraulic nut (3).
8. Connect HP line (6) to adapter.
10. Back off nut (5) for a distance equaling push-on
dimension.
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11. Fill hand pumps (1) and (2) with engine oil SAE 10.
12. Vent hand pumps (1) and (2) and line system until
14. Operate hand pump (2) to bring hydraulic nut at
minimum pressure p
2
(start of pressure increase)
to attachment with drive flange.
15. Read off max. expansion pressure p
max
at
drive flange.
16. Actuate hand pump (1) to expand the drive flange
until half the maximum expansion pressure p
1
has been reached.
1
18. Increase expansion pressure gradually in
steps of 0.1 x p
max
with hold times of approx.
2 minutes until the drive flange comes clear off the
crankshaft. Do not exceed maximum expansion
pressure p
max
.
pressure.
2
of the drive flange from the taper seat is indicated
by rising pressure p
2
.
21. Gradually relieve pressure in hydraulic nut while
steadily operating pump for expansion fluid.
22. Relieve hand pumps (1) and (2).
23. Screw eyebolt into drive flange and suspend drive
flange on crane with rope lightly tensioned.
24. Remove installation/removal tool.
25. Remove drive flange (1) from crankshaft (2).
26. Remove screws (4) from adapter flange (3).
27. Remove adapter flange (3).
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9.3.22 Vibration damper on PTO, free end Disassembly
Vibration damper Disassembly
This component is an exchange component (Reman) and is available via the normal exchange procedure.
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9.3.23 Vibration damper on PTO, free end Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning vibration damper
2. Remove cleaner.
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9.3.24 Vibration damper on PTO, free end Check
Special tools
Bore gauge, 160-280 mm Y20091483 1
Micrometer, 175-200 mm Y20001744 1
Holder 0015890321/00 1
Spare parts
Vibration damper
Drive flange
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Vibration damper - Check
Item Findings Task
Visually inspect vibration damper for
damage and wear.
Damage
Wear
visible
Replace vibration damper.
Using a precision bore gauge,
measure vibration damper bore.
Values ( Page 1175)
Values exceeded. Replace vibration damper.
Measure drive flange OD with
micrometer. Values ( Page 1175)
Values below specification. Replace drive flange.
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9.3.25 Vibration damper on PTO, free end Tolerances
limit
Basic
size
lower
upper
min.
max.
min.
max.
ID of vibration
damper
198.000
H7
0 +0.046 0 0.059 0.016 1
OD of driver
flange
196.00
j6
0.013 +0.016
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9.3.26 Vibration damper on PTO, free end Installation
Special tools
Removal/installation device F0140771 1
Hook-ended chain sling (quadruple branch) T80090748 1
Material
Engine oil
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
WARNING
CAUTION
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Installing adapter flange
1. Coat O-rings with grease and insert into groove.
2. Install adapter flange with O-rings as shown in the overview drawing ( Page 1167).
3. Use torque wrench to tighten screws to specified tightening torque ( Page 980).
Hydraulic press-fitting drive flange
1. Clean, degrease and dry tapers of crankshaft
and vibration damper.
2. Coat running surfaces of crankshaft bearing and
drive flange with oil.
3. Push drive flange onto crankshaft taper by hand.
4. Measure distance from crankshaft end face to
drive flange end face using depth gauge and
note measured value.
5. Calculate difference (= push-on distance) between
measured dimension and push-on dimension
( Page 1167).
6. Push-on dimension B = distance between
crankshaft end face and drive flange end face
after installation.
7. Read off push-on distance at drive flange.
8. If calculated push-on distance is less than
measured value, check dimensional accuracy
of tapers.
9. Screw puller spindle (4) into crankshaft.
10. Check reference dimension (A) ( Page 1167).
11. Mount installation/removal device as shown in the
12. Slide thrust sleeve (1) and hydraulic nut (3)
over puller spindle.
13. Set hydraulic nut (3) to initial position at zero
stroke.
14. Install nut (5) and hand-tighten.
15. Screw high-pressure line with connecting piece (2)
into drive flange.
16. Connect high-pressure line (6) of hydraulic unit
to hydraulic nut (3).
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17. Fill hand pump (1) and (2) with engine oil acc.
to SAE 10 W.
18. Vent hand pump (1) and (2) and pipework until
19. Tighten high-pressure line.
20. Prior to hydraulic press-fitting, moisten tapers fit
with expansion fluid. For this purpose, actuate
hand pump (1) until expansion fluid emerges
at drive flange end.
21. Operate hydraulic hand pump (2) for hydraulic
nut and, by applying minimum pressure on drive
flange, seat against drive flange.
22. Pump in expansion fluid until expansion pressure
p
1
no longer rises. Then increase press-on force
by raising force-on pressure p
2
.
23. Repeat this process until drive flange is correctly
seated.
24. Select push-on pressure so as to achieve
positioning in approx. 5 steps.
25. Read off expansion pressure p
max
at drive flange.
Ensure that, during installation, the required
expansion pressure is less than the maximum
expansion pressure p
max
.
Result: Hydraulic installation is completed when
thrust sleeve is seated against crankshaft.
expansion pressure.
28. Disconnect high-pressure line.
29. Remove installation/removal device after specified
hold time has elapsed.
30. Check push-on dimension (B) between crankshaft
end face and drive flange end face ( Page 1167).
31. If push-on dimension is not established,
hydraulically remove drive flange and determine
the cause.
32. Do not subject press fitting to operating load
for at least 8 hours.
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Installing vibration damper
1. Screw adjusting mandrels (1) into threaded hole
of drive flange.
2. Coat O-rings (2) with grease.
3. Fit O-rings (2) on drive flange.
4. Attach vibration damper (1) with lifting gear (3) and
support bracket to crane using a lightly tensioned
hook-ended chain sling.
5. Push vibration damper (1) onto adjusting
mandrels (2).
6. Remove lifting gear (3).
7. Coat thread and screw head mating faces with
engine oil and screw in.
8. Remove adjusting mandrels.
9. Install remaining screws and washers and tighten
to specified tightening torque ( Page 980)
using a torque wrench.
10. Install protective cover.
11. Remove positioning fixture from end housing.
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9.3.27 Piston and conrod Overview
Piston and conrod
1 Piston
2 Conrod
3 Conrod cap
4 Conrod bearing shell, upper
5 Conrod bearing shell, lower
6 Conrod screw
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Piston details
1 Snap ring
2 Piston pin
5 Oil control ring
6 Piston
7 Pressure plate
8 Piston crown screw
9 Conrod
10 Conrod cap
11 Conrod screw
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9.3.28 Piston and conrod Removal
Special tools
Barring tool, 8V-16V F6555766 1
Barring tool, 20V F6783293 1
Barring tool for timing disc F6555791 1
Socket, 22 A/F, conrod screws F30378352 1
Lifting device for piston removal, 8V-16V T80091025 1
Lifting device for piston removal, 20V T80091496 1
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Removing piston and conrod with oil pan installed
1. Remove combustion residues from cylinder liner.
2. Remove carbon scraper ring (arrowed)
( Page 1034).
3. Install barring tool.
4. Remove left and right-side inspection port cover on
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6. Working through the inspection port (arrowed),
slacken conrod screws using a socket insert and
large ratchet.
7. For further removal, except for altered removal
position of crankcase: see "Removing piston and
conrod in assembly dolly" in next section.
8. Before removing the conrod from cylinder liner (3),
attach sliding block (2) to conrod (1).
Removing piston and conrod in assembly dolly
Note: Do not bar crankshaft unless the flywheel
or axial locating device is installed.
1. Turn crankcase in assembly dolly until conrod
bearing cap (1) of the piston to be removed
is horizontal.
2. Using socket (2), extension and ratchet, release
conrod screw (3).
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Note: Bearing cap and conrod are a single unit
and must not be interchanged.
3. Check marking (arrowed) of conrod bearing cap
and conrod. If necessary, mark components.
4. Remove conrod screws (arrowed) and take off
conrod bearing cap (1).
5. Remove bearing shell from conrod bearing cap.
Ensure that toothing on mating faces of conrod
and conrod bearing cap is not damaged.
6. Protect bearing shell and conrod bearing cap
from damage.
7. Check markings of bearing shell to conrod. If
necessary, mark components.
8. Turn crankcase in assembly dolly until the piston
and conrod to be removed are vertical. Ensure
that the oil spray nozzle is not damaged.
9. Remove bearing shell from conrod and protect
from damage.
10. Attach lifting device (1 ) to piston crown (2).
11. Using a crane, withdraw piston and conrod from
cylinder liner fit.
12. Carefully set down piston and conrod on soft
surface and remove from crane.
13. Remove lifting device from piston crown.
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9.3.29 Piston and conrod Disassembly
Special tools
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Removing conrod from piston
1. Place piston and conrod on workbench.
2. Check markings of conrod, piston and piston pin. If
necessary, mark components anew.
3. Using snap ring pliers (1), remove snap ring (2).
4. Use a piece of round wood to press out piston pin
(2), holding conrod (1) firmly in position.
5. Remove conrod from piston.
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Removing piston rings
1. Stretch piston rings until they can be removed
from the piston.
2. Remove piston rings with piston ring pliers in
sequence from top to bottom.
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9.3.30 Piston Cleaning
Material
Cleaner (Sima Solv K6) 50632 1
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
Wear goggles/facial protection.
Only work in a well-ventilated room.
Do not smoke.
WARNING
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
Piston cleaning
Note: The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners!
1. Clean all metallic parts with the cleaner.
2. Clean area of piston ring grooves with rotating plastic brush.
3. After cleaning, blow out oil chamber and oil bores with compressed air.
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9.3.31 Piston Check
Material
Spare parts
Piston
Piston pin
Oil-control ring
Taper-face compression ring
Rectangular-section ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
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Piston Check
Item Findings Task
Make sure that oil chamber and oil
bores are particularly clean.
Not clean Clean
Check piston with fluorescent
penetrant.
Signs of cracks Replace piston.
Check piston for wear Contact erosion at piston edge
and valve clearance pockets
Large area of polishing wear
on piston skirt (appears dull)
Concentrated occurrence of
scoring
Pitting
Replace piston.
Measure piston pin boss. Values
( Page 1191)
Values exceeded Replace piston.
Check sliding surface of bronze
bush for stress marks and scoring.
Stress marks
Scores
visible
Replace piston.
Check groove width with gauge
blocks. If no gauge block is
available, alternatively a new piston
ring can be inserted in the groove
and the axial play checked with a
feeler gauge. Values ( Page 1191)
Values exceeded. Replace piston.
Check piston pin with magnetic
crack-testing method for cracks.
Signs of cracks Replace piston pin.
Check condition of piston. Traces of wear
Scores
Impact points
visible
Replace piston pin.
Measure outer piston pin diameter
with C-frame micrometer. Values
( Page 1191)
Values exceeded. Replace piston pin.
Check piston rings. Piston ring with burring,
chipping or sharp edges
If chrome layer has signs
of scoring, cracks or heat
discoloration.
Replace
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Piston rings Check
1. Place piston ring (1) in ring gauge (3) to measure
piston ring end clearance. Ensure that piston ring
fits evenly in ring gauge.
2. Check ring end clearance with feeler gauge (2).
3. If values are exceeded ( Page 1191), replace
piston rings. Replace piston rings only in sets.
4. After installation of new piston rings, replace
cylinder liners ( Page 1034).
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9.3.32 Piston Tolerances
Piston bearing
Deviation Clearance Interference Wear limit No. Designation Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
Bush inner
dia.
68.000 +0.070 +0.080 1
Piston pin
outer dia.
68.000 0.005 0
0.070 0.085 Clearance max.
0.090
Bush inner
dia.
68.000 +0.012 +0.022 2
Piston pin
outer dia.
68,000 0,005 0
0.025
3 MTU part number and stage stamped on
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Piston rings
tion
Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
Groove
width
4,000 +0,170 +0,190 1
Rectan-
gular-sec-
tion ring
4,000 0,035 0
0.300
Groove
width
4,000 0,080 0,100 2
Taper-
face com-
pression
ring
4,000 0,035 0
0.200
Groove
width
5,000 +0,080 +0,100 3
Oil control
ring
5,000 0,035 0
0.200
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tion
Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
Joint clearance Clearance max.
Rectan-
gular-sec-
tion ring
0,400 0,700 0,900
Taper-
face com-
pression
ring
1,000 1,300 1,500
Oil control
ring
0,450 0,800 1,000
4
Measure joint clearance in ring gauge 165.000
H6
.
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Piston clearance in cylinder liner
limit
Basic size
lower
upper
min.
max.
min.
max.
Cylinder liner
dia.
165.000
H7
0 +0,040 1
Piston skirt
dia.
164,805 0,011 +0,011
0,184 0,246
Cylinder liner
dia.
165.000
H7
0 +0,040 2
Piston skirt
dia.
164.720 0.010 +0.010
0,270 0,330
Cylinder liner
dia.
165.000
H7
0 +0.040 3
Piston crown
dia.
164.580 0.020 +0.020
0.400 0.480
Cylinder liner
dia.
165.000
H7
0 +0.040 4
Piston crown
dia.
164.525 0.020 +0.020
0.455 0.495
Scraper ring
dia.
164.000
H8
0 +0.063 5
Piston crown
dia.
163.390 0.025 +0.025
0.585 0.698
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limit
Basic size
lower
upper
min.
max.
min.
max.
Dimensions 1 to 5 measured vertically in relation to pin axis.
Scraper ring
dia.
164.000
H8
0 +0.063 6
Piston crown
dia.
163.267 0.025 +0.025
0.708 0.821
7 Piston skirt round falling oval
Skirt graphite-coated with two positions at 1 and 2 respectively free of graphite for measuring the diameter.
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Piston crown mounting
limit
No. Designation Stage Tol.
size
Basic
size
lower
upper
min.
max.
min.
max.
49.000 0.100 +0.100
max.
length
49.800
1 Screw length
removed
50.000 0.100 +0.100
max.
length
50.800
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9.3.33 Conrod Disassembly
Spare parts
Conrod
Conrod Disassembly
1. Disassembly of conrod is not planned.
2. The conrod is an exchange component (Reman) and is available via the normal exchange procedure.
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9.3.34 Conrod Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Conrod Cleaning
2. Clean conrod oil bore with hole brush.
3. Use a brass brush to clean meshing on conrod and conrod bearing cap mating faces.
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9.3.35 Conrod Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Bore gauge, 100-160 mm Y20091482 1
Material
Spare parts
Conrod
Conrod screw
WARNING
Compressed air.
Risk of injury!
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Conrod Check
Item Findings Task
Check conrod main bore for blue
discoloration.
Blue discoloration Replace conrod.
Check conrod bushing for scores,
contamination, stress marks and
heat discoloration marks.
To be carried out only in
Replace conrod bush.
Check conrod, conrod bearing cap
and conrod bearing screws for
cracks using magnetic crack-testing
method.
Check threads of conrod and conrod
screw for damage.
Damaged Replace conrod.
Replace conrod screw.
Check conrod screw length. Values
( Page 1206)
Value exceeded Replace
Check basic bore for stress marks
and scores.
Stress marks
Scores
visible
Corrective work
Replace
Inspect meshing for damage and
check wear pattern with engineers
blue.
Damaged Replace
Measuring conrod basic bore
1. Assemble conrod ( Page 1210).
2. Before measuring, rub down basic bore (2) with
emery cloth.
3. Adjust bore gauge (1) and measure main conrod
bore ( Page 1206).
4. If values are exceeded, replace conrod.
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Measuring conrod main bore with bearing shells
1. Coat sliding surfaces of bearing shells with
engine oil.
2. Measure conrod bearing bore. Values
( Page 1206).
3. Enter measured values in data sheet.
4. Replace bearing shells if limit values are fallen
short of or exceeded.
5. Remove conrod screws, conrod cap and bearing
shells.
Measuring conrod bush from piston pin end
1. Set bore gauge (1) to zero dimension of conrod
bushing bore and measure conrod bush bore (2).
Values ( Page 1206).
2. Values exceeded: Replace conrod bush only in
Checking conrod bush axial fit
1. Use test mandrel (1) and hydraulic press to
check conrod bush axial fit. Required test force F
( Page 1206).
2. If test force is not reached, replace conrod.
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1 Dial gauge for axial parallelism
2 Test mandrel, small conrod bore
3 Dial gauge for conrod twist
4 Conrod
5 Test mandrel, large conrod bore
6 V-block
7 Base plate
8 Resilient stop
9 Adjustable dial gauge holder
Checking conrod bore axial parallelism and twist
1. Before inspection, install conrod bearing cap and
tighten conrod bearing screws.
2. Insert test mandrel (2) in large conrod bore so that
and narrow fit faces conrod bearing cap.
3. Clamp test mandrel (2) firmly with locking screw,
ensuring that test mandrel (2) does not tilt.
4. Insert test mandrel (1) in small conrod bore so that
and narrow fit faces oil bores of small conrod bore.
5. Clamp test mandrel (1) with locking screw.
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Checking axial parallelism
(4) of testing device.
2. Place test mandrel (2) on spring-mounted stop (5).
3. Adjust the rigid stop of adjustable stop so that
axle of test mandrel (2) is approx. 2.0 mm below
dial gauge pointer (1).
4. Adjust dial gauges so that their readings indicate
approx. 2 mm preload at highest point on test
mandrel axis, and set to zero.
5. Turn conrod through 180 and carefully place in
testing device.
6. Move test mandrel (2) through dial gauge pointers
at highest point on mandrel axis.
7. Determine and record deviations from zero on dial
gauges.
Checking axial twist
1. Set both dial gauges (1) for axial twist with setting
gauge (2) via dial gauge pointer to zero.
2. Remove setting gauge (2) from testing device (3).
(3) of testing device. Fixed support of adjustable
stop is set so that dial gauge pointer travel is
approx. 2 mm.
4. Press conrod at small conrod bore on fixed
support.
5. Read off and note values on dial gauges (1).
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Calculating axial parallelism
Note: The testing device is set for measuring
axial parallelism at 200 mm intervals.
1. In order to obtain the correct value to 100 mm
clearance ( Page 1206), calculate recorded
value on dial gauges as shown in the following
example.
Description Value
Left dial gauge A = 0.05 mm
Right dial gauge B = +0.03 mm
Result = 0.08 mm
Result: Axial parallelism: 0.08 mm : 4 = 0.02 mm
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Calculating axial twist
1. To determine axial twist of conrod bores, calculate
value measured at 100 mm intervals as shown in
example.
Description Value
Left dial gauge A
1
= 0.06 mm
Right dial gauge A
2
= +0.04 mm
Difference = 0.10 mm
Result: Axial twist A = 0.10 mm : 2 = 0.05 mm
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9.3.36 Conrod Tolerances
Conrod bearings
Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
H6
0 +0.025
0 - 0 117.082
0 - 1 116.882
0 - 2 116.682
Conrod bearing
bore
Conrod bearing
installed
0 - 3 116.482
0 +0.048
0 - 0 117.000 h6
0 - 1 116.800 h6
0 - 2 116.600 h6
2
Crankpin
0 - 3 116.400 h6
0.022 0
0.082 0.152
Crankpin length 97.500 0.100 +0.100 3
0.200 0.600
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Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
0 - 0 126.400
0 - 1 126.400
0 - 2 126.400
4 Expanding
dimension
Conrod bearing
shell, upper and
lower part
0 - 3 126.400
0 +1.000
Conrod screw length
Basic
size
lower
upper
min.
max.
min.
max.
1 Screw length
removed
103.000 0.400 +0.200 104.500
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Conrod bore parallelism
Basic
size
lower
upper
min.
max.
min.
max.
1 Conrod length
8/12/16V
354.000 0.100 +0.100
1 Conrod length
20V
364.000 0.100 +0.100
2 Axial parallelism
Inclination
0.070 over a distance of 100 mm Inclination
max. 0.100
3 Axial parallelism
Twist
0.250 over a distance of 100 mm Offset
max. 0.350
Conrod weight
8/12/16V
9.530 kg -0.060
kg
+0.060
kg
Conrod weight 20V 9.580 kg -0.060
kg
+0.060
kg
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Small conrod bore
Basic
size
lower
upper
min.
max.
min.
max.
0 75.000 H6
1 75.200 H6
Conrod bore
2 75.400 H6
0 +0.019
0 75.000 v6
1 75.200 v6
1
Conrod bushing
outer dia.
2 75.400 v6
+0.120 +0.139
0.101 +0.139
2 Conrod bushing
inner dia.
68.000 +0.070 +0.080
F Axial test force for 8/12/16V conrod: 17,000 N (tested conrod bushings are marked "X")
F Axial test force for 20V conrod: 30,000 N (tested conrod bushings are marked "X")
A Edges rounded
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9.3.37 Conrod Assembly
Special tools
Socket, SW 22 Conrod screws F30378352 1
Material
Engine oil
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
Preparing conrod
1. Blow out mating faces (arrows) on conrod and
conrod bearing cap with compressed air and clean.
conrod bearing cap.
3. Before installing bearing shells, compare repair
stage data on conrod and on crankshaft data
sheet.
4. Mark bearing shells according to cylinder number
on end face.
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5. Insert lower conrod bearing shell (2) with securing
lug (arrow) in groove of conrod bearing cap (1).
6. Clamp conrod in assembly trolley or in bench
vise with aluminum jaws with mating face in
horizontal position.
7. Insert upper conrod bearing shell (2) with securing
lug (arrow) in groove of conrod (1).
onto conrod.
9. Coat threads of conrod bearing screws and screw
head seating surfaces with engine oil.
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Note: Thread must not be recut.
10. Carefully insert conrod bearing screw into bore in
conrod bearing cap by hand until initial contact
with thread flanks is established, then turn first
three turns without a tool.
11. Install conrod bearing screws until screw heads
make contact and use socket wrench to tighten
firmly by hand. Ensure that conrod and conrod cap
serrations is closed at short and long conrod arms.
12. Use torque wrench (1) to tighten conrod bearing
screws to specified tightening torque . Tightening
sequence:
12.1.Short arm
12.2.Long arm
Conrod screw M20 x 1.5 Preload torque Engine oil 240 Nm +20 Nm
Conrod screw M20 x 1.5 Residual angle of rotation 90 +10
Conrod screw M20 x 1.5 Control torque 450 Nm +20 Nm
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9.3.38 Piston Assembly
Special tools
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Installing piston rings
1. Turn coiled spring expander (2) in oil control ring
(1) in order to offset ring spring butting face (arrow)
to oil control ring butt by 180.
3 Oil control ring
2. Prepare piston rings as per installation sequence.
Note that new piston rings must be replaced in
sets.
3. After replacing piston rings, replace cylinder
liners ( Page 1034).
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4. Stretch piston rings with pliers so that they can be
fitted over the piston.
5. Insert piston rings in sequence from bottom
upwards (oil control ring first) in the annular
grooves on the piston so that the TOP marking on
the piston rings faces the piston crown.
6. Check that piston rings move freely in their
grooves.
7. Wipe down piston pin, conrod bushing and piston
pin bore with chamois leather and coat with
engine oil.
8. Insert conrod (1) according to markings into
relevant piston (2) in such a way that the shorter
end (A) of the angle-split conrod faces piston
cooling oil bore (B).
9. Insert corresponding piston pin (2) in piston and
conrod (1) until it makes contact with installed
snap ring.
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10. Use snap ring pliers to insert second snap ring.
11. Ensure snap ring is perfectly seated and correctly
positioned (arrow).
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9.3.39 Piston and conrod Installation
Special tools
Lifting tool for piston T80091025 1
Piston/conrod assembly sleeves for carbon scraper ring F6557121 1
Barring device for graduated disc F6555791 1
Pointer for barring device F6555792 1
Measuring equipment for TDC measurement in cylinder head Y4341919 1
Socket A/F 22 conrod screws F30378352 1
Material
Engine oil
DANGER
Suspended load.
Danger to life!
WARNING
Heavy object.
Risk of crushing!
CAUTION
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Preparing crankcase
1. Move crankpin of respective cylinder on right
engine side to 40 before TDC and on left engine
side to 40 after TDC.
2. Before installing piston with conrod, fit sliding
block (2) on the conrod (1) to be installed.
3. Wipe crankpin and running surface of cylinder liner
with chamois leather and spray with engine oil.
Preparing piston for installation
1. Spray piston and piston rings with engine oil.
2. Ensure that piston ring joints (arrowed) are evenly
arranged at 120 around piston circumference.
3. Center piston rings and oil control ring in grooves.
Preparing conrod bearing for installation
1. Blow joint faces (arrows) on conrod bearing
cap and conrod with compressed air and check
cleanness.
conrod bearing cap with chamois leather.
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3. Make sure that the lower conrod bearing shell (2)
with locking lug (arrow) is properly seated in the
conrod bearing groove (1).
4. Coat sliding surfaces of conrod bearing shells
with engine oil.
Note: In order to guide the conrod and avoid damage
to the oil spray nozzle, piston installation must
be carried out by two people. Install piston with
carbon scraper ring removed.
Installing piston and conrod in cylinder liner
1. Install lifting tool (1) for piston.
2. Place piston assembly sleeve (2) with chamfered
side up on cylinder liner.
3. Oil assembly sleeve and cylinder liner inside.
4. Install piston in cylinder liner making sure that the
short arm of the conrod points outwards to the
air intake side. Turn piston slightly so that the oil
spray nozzle is not damaged.
onto conrod.
Installing conrod bearing cap
1. Coat thread and screw-head mating face with engine oil.
2. Insert conrod bearing screws into screw bore on conrod cap by hand, then turn first three rotations without
a tool.
3. Fit conrod bearing screws up to screw head and tighten firmly by hand using socket wrench, ensuring that
conrod serrations are closed.
4. Pretighten conrod screws with torque wrench to specified tightening torque ( Page 980).
5. Check conrod axial movement.
6. Tighten conrod screws with torque wrench to specified tightening torque ( Page 980).
7. Check conrod axial clearance.
8. Remove lifting tool and assembly sleeve for piston with conrod and take off.
9. Turn crankshaft and ensure that there is ease of movement between oil spray nozzle, piston and conrod.
10. Remove lifting tool after installation.
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Checking conrod axial clearance
1. Use feeler gauge to check distance between crankshaft web and conrod and between conrod and conrod,
pressed towards each other.
2. If axial clearance is below the minimum of 0.20 mm or above the maximum of 0.60 mm, measured pressed at
three levels, readjust clearance.
3. Release conrod bearing screws and compensate axial clearance.
4. Using a torque wrench, first pretighten conrod cap screw on short conrod arm and then on long conrod
arm to specified tightening torque ( Page 980).
5. Re-check axial clearance.
6. Tighten conrod bearing screws with torque wrench to prescribed tightening torque ( Page 980).
1. Coat edge of cylinder liner and carbon scraper
ring with engine oil.
2. Insert carbon scraper ring.
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9.4 Cylinder Head
9.4.1 Cylinder head and attachments Overview
Cylinder head and attachments Overview
1 Cylinder head
2 Inlet valve
3 Exhaust valve
4 Valve spring, inner
5 Valve spring, outer
6 Spring retainer
7 Valve collet
8 Valve rotator
10 Plug screw
11 Sealing ring
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2 Valve-seat insert, inlet *
3 Valve-seat insert, exhaust *
4 O-ring
5 Sleeve
6 Valve guide
7 Plug
8 Plug
9 Plug
11 Cylinder head
* Only on cylinder heads of
corresponding design
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1 Sealing ring
2 Gasket
4 Thrust washer
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9.4.2 Valve-seat turning machine for cylinder head
Working principle of valve-seat turning machine
The valve-seat turning machine is an inside turning device. While the cutter (3) rotates around the valve-seat
(5), a feed gear mechanism ensures a continuous outward feed motion (1). The feed motion under the proper
valve-seat angle (4) is defined by an inclined slideway in the exchangeable adapter head.
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Installing the solid pilot
Precondition:
Valve guide is installed and machined to finished dimension.
Valve guide was cleaned.
Cylinder head is securely clamped and valve guide accessible from both sides.
Mounting the supporting spider
To achieve maximum accuracy, the pilot must be supported by the supporting spider (7) below the valve seat. Slide
the supporting spider (7) over the pilot shaft to such position that the spring-loaded spider elements (1) rest just
below the valve seat level when the pilot is installed in the valve guide (4) and tighten the clamping screw (6).
Inserting the pilot into the valve guide
Remove clamping nut (3) from pilot and insert the threaded end of the pilot into the valve guide (4), until
the tapered portion (5) bears against the conical seating of the valve guide (4). The spring-loaded elements
(1) of the spider (7) will bear against the exhaust/inlet canal below the valve seat.
Locking the pilot
Screw clamping nut (3) onto the pilot and tighten with moderate force. Tighten the screws (6) on
top of the spider to lock the spring-loaded elements (1) of the spider (7). Apply standard machine
oil to the top and around the periphery of the pilot shaft.
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Setting up valve turning machine
Mounting the cutter
Fit the appropriate tool holder of the cutter (8) with an indexable insert and attach to the tool slide (7).
Placing the valve-turning machine on the pilot
Take care that the cutter (8) does not bump against the cylinder head.
Slide the valve-seat cutting machine over the pilot (10) until either the depth stop (3) rests upon
the pilot (10) or the cutter (8) contacts the cylinder head.
Aligning the cutting edge with the valve-seat center
Turn rapid tool adjuster (11) to position cutting edge of cutter over the valve-seat center (9). Hold
the machine with one hand. Loosen screw (4) of depth stop (3) and allow machine to slide down
until the cutting edge contacts the valve seat (9) lightly. Push depth stop (3) slightly downward
against the pilot (10) and then tighten depth stop locking screw (4).
Connecting the machine to power supply
Insert the round plug of the outlet cable (6) of the power supply unit (5) into the corresponding socket
(1) on the driving assembly (2) and allow the securing latch to engage.
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Valve seat turning
Positioning the cutter at the inner valve-seat edge
Slightly lift machine with one hand and then turn rapid tool adapter (11) with the other hand until the
cutting edge is just clear of the inner edge of the valve seat (10).
Setting cutting depth
To set the depth of cut, turn depth feed (3) counterclockwise. One notch of the depth-feed scale (4) corresponds
to a depth feed of 0.025 mm. As the valve seat (10) usually shows unequal wear, the depth of the first turning
cycle must be selected (max. 0.2 mm) to ensure that the entire valve-seat surface is undercut.
If the cutting edge is just scraping along the surface instead of undercutting the hard surface zone,
there is a risk of premature wear and chipping of the cutting edge.
Lubricating the valve seat
Apply a few drops of metalworking lubricant on hard valve-seat surfaces before turning.
Valve seat turning
Make sure that the pivoted lever (8) is engaged in the groove of the feed actuator (12). Select proper speed by
shifting the switch (6) at the power supply unit (5). Speed can be increased by changing over from 30 VDC to 42 VDC.
Hold driving unit (2) with both hands at the motors (1) and press pushbutton switch (7) to start the cutting pass.
Release the pushbutton switch (7) as soon as the cutter has been traversed beyond the top edge of the valve seat (10).
Repeating the cutting pass
Repeat steps with a cutting depth between 0.05 mm and 0.1 mm until the valve seat surface (10) is plane all around.
To ensure a smooth valve-seat surface (10) finish, proceed with a final pass at high speed with 0.025 mmcutting depth.
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Replacing the adapter head
Removing the adapter head
Unscrew the two screws (1) from the adapter head (2).
Turn adapter head (2) in the direction of the arrow until the back of the toothed rack (4) is no longer engaged with
the pinion (4) in the gear housing (6). Now the adapter head can be withdrawn off the gear housing (6).
Mounting the adapter head
Place adapter head (2) onto gear housing (6) so that the pinion (5) projecting from the gear housing (6)
is seated in the corresponding bore of the adapter head (2).
The adapter head (2) must be seated flush with the gear housing (6).
Screw the two screws (1) loosely into the gear housing so that the adapter head (2) can still be moved
to adjust proper clearance between toothed rack (4) and pinion.
Adjust the adapter head so that the gap between the toothed side of the rack (4) and the opposite side of
the recess (3) is approximately 0.3 mm to 0.5 mm. Tighten both screws (1).
Turn the rapid tool adjuster to move the tool slide back and forth. If tool slide does not
move freely, readjust the adapter head.
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9.4.3 Cylinder head Removal
Preconditions
Special tools
Plug B80144872 1
Installation/removal tool for plugs F30378956 1
WARNING
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
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Cylinder head Removal
1. Release hex bolts (1) on the cylinder head with
power amplifier (2) evenly and unscrew.
2. Screw plug (2) on to installation/removal tool and
lock it by turning the handle (1).
3. Screw plugs with installation/removal tool (1) into
oil supply line (arrow) in crankcase and spread.
4. Ensure that the plug is firmly anchored.
5. Release installation/removal tool (1) and remove.
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6. Suspend cylinder head (2) with support bracket (1)
on crane with rope lightly tensioned.
7. Lift off cylinder head (2) and lower onto a firm
surface.
8. Remove cylinder head gasket from mating face
of crankcase.
9. Remove plug from oil supply bore and close
with protective plug.
10. Use a screwdriver to remove sealing ring from
lower side of cylinder head.
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9.4.4 Cylinder head Disassembly
Special tools
Socket F30377634 1
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
Risk of injury!
Removing valves
1. Place cylinder head on base plate (3).
2. Mount valve-spring compressor (2).
with valve-spring compressor (2) until the valve
collets (4) can be removed.
4. Remove valve collets (4) with a magnet.
5. Release valve springs and remove valve-spring
compressor (2).
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6. Remove valve spring retainer, valve springs
and valve rotators.
8. Mark exhaust and inlet valves so that they can be
reinstalled in their original positions.
9. Place valves in storage rack (1).
Removing sleeve
1. Secure cylinder head.
2. Using socket, remove sleeve from cylinder head.
3. Remove O-ring from sleeve.
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9.4.5 Cylinder head Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
CAUTION
Cleaning the cylinder head
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9.4.6 Cylinder head Check
Special tools
Check gauge for inlet valve seat Y4340442 1
Check gauge for exhaust valve seat Y4340443 1
Removal tool Y4343688 1
Material
Corrosion inhibitor
Spare parts
Cylinder head
Sealing ring
Gasket
Thrust washer
Valve guides
Valves
Sleeve
Valve springs
Sliding pin
Valve rotator
Spring retainer
Valve collet
WARNING
Compressed air.
Risk of injury!
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WARNING
Heavy object.
Risk of crushing!
WARNING
Cylinder head check
Item Findings Task
Measure cylinder head height.
Values ( Page 1237)
Minimum height not reached Replace cylinder head.
Check cylinder head mating face
(combustion chamber side) for
Damaged Recondition
Check mating face of sleeve in
cylinder head for scores and wear.
Scores
signs of wear
visible.
Recondition
Measure valve guides with alignment
plug gauge. Values ( Page 1237)
Not dimensionally accurate Replace valve guides.
Check valve springs for damage.
Check spring power and
length of valve springs. Values
( Page 1237)
Damaged
Values below specification
Replace valve springs
Check thread for ease of movement. Sluggish Recondition
Check valve seats on cylinder head
for pitting and wear.
Pitting or wear Recondition: ( Page 1223)
Check cylinder head screw threads,
screw head mating faces and thrust
washer for damage.
Damaged Replace
Values exceeded ( Page 1237). Replace
Check valves for damage.
Check valves for concentricity and
dimensional accuracy. Values
( Page 1237)
Chrome layer damaged
Valve keyways damaged or
burnt
Out-of-round
Replace
Check spring retainer and valve
collet for scores and wear.
Scores
signs of wear
visible.
Replace
Replace valve guides and valve rotators during extended component repair.
Only for cylinder heads with valve bridge guides.
Check sliding pin and valve bridge
bore for wear and damage. Values
( Page 1237)
Signs of wear
Damage visible
Not dimensionally accurate
Replace sliding pin.
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Checking cylinder head for leaks
Note: Install sleeve prior to leak test ( Page 1257).
2. Install pressure testing device.
3. Place cylinder head in a water bath heated to 80 C until cylinder head has warmed up.
4. Pressure-test cylinder head with 0.5 bar compressed air.
5. Pressure must be maintained with cylinder head in water bath for at least 30 minutes. No air bubbles must
emerge.
6. Remove hydraulic pressure testing device.
7. Replace leaking sealing cover ( Page 1255).
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9.4.7 Cylinder head Tolerances
Cylinder head tolerances for heads with valve seat inserts and
exhaust emission certification
Inlet and exhaust valve guides
Basic
size
lower
upper
min.
max.
min.
max.
0 19.000
H7
1 19.100
H7
Cylinder head
bore
2 19.300
H7
0 +0.021
0 19.000
r6
1 19.100
r6
1
Valve guide
external
diameter
2 19.300
r6
+0.028 +0.041
+0.007 +0.041
Valve guide bore
installed
11.000
H7
0 +0.018 2
Valve stem
diameter
10.935 0.010 +0.010
0.055 0.093
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Basic
size
lower
upper
min.
max.
min.
max.
Finished valve
guide bore
installed
11.000
H9
0 +0.043 2
Valve stem
diameter
10.935 0.010 +0.010
0.055 0.118
Valve clearance
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve protrusion
Exhaust
with valve seat
ring
+0.100 up to max.
1.000
2 Valve clearance
or protrusion
Inlet
0.000 up to max.
1.100
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Inlet and exhaust valve seat ring
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve seat ring
bore, exhaust
57.000
H6
0 +0.019
2 Valve-seat insert
- depth
11.200 0.050 +0.050
3 Valve-seat insert
bore, inlet
58.000
H6
0 +0.019
If a valve-seat insert is replaced before reaching the reconditioning depth of 1.100 mm, it must be machined
to the depth of the contour to avoid that the valve-seat insert protrudes into the combustion chamber.
Max. corrective machining or equalizing of valve-seat inserts by 0.300 mm in depth, without machining the
contour and the radius.
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Inlet and exhaust valve-seat insert
Basic
size
lower
upper
min.
max.
min.
max.
1 Plug gauge
diameter
73.200 0 0
2 Plug gauge
diameter
87.130 0 0
3 Valve seat
surface
Reference
dimension
Plug gauge
4.800 0.200 +0.200 up to min.
3.700
4 Cylinder head
depth
Combustion
chamber sealing
ring surface
13.800 0 +0.100
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Inlet valve elliptical chamfer
Basic
size
lower
upper
min.
max.
min.
max.
1 Distance to valve
seat center
2.700 0.150 +0.150
2 Chamfer 0.300
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Exhaust valve
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve head
external
diameter
56.000 0.200 +0.200
Reference
dimension
with ring gauge
for
valve seat
diameter
54.000 2
3.480
3 Reference
dimension
without ring
gauge for
valve seat height
3.700 0.200 +0.100 up to min.
3.000
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Inlet valve
Basic
size
lower
upper
min.
max.
min.
max.
1 Valve head
external
diameter
57.000 0.200 +0.200
Reference
dimension
with ring gauge
for
valve seat
diameter
54.000 2
3.350
3 Reference
dimension
without ring
gauge for
valve seat height
3.700 0.200 +0.100 up to min.
3.000
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Valve springs, outer
Basic
size
lower
upper
min.
max.
min.
max.
1 Spring length
released
83.900
Spring length
compressed
66.000 2
Spring length
when mod. valve
rotator is used
65.100
2.1 Spring force
at compressed
spring length
530.000 N
Spring length
compressed
51.750 3
Spring length
when mod. valve
rotator is used
50.850
3.1 Spring force at
spring length
pos. 3
952.000 N 39 N +39 N Spring
force
min. 897.000 N
4 Spring length
Block dimension
47.700 Block
dimension
max. 47.700
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Basic
size
lower
upper
min.
max.
min.
max.
6 Wire dia. 5.300
Valve springs, inner
Basic
size
lower
upper
min.
max.
min.
max.
1 Spring length
released
78.400
Spring length
compressed
61.000 2
Spring length
when mod. valve
rotator is used
60.100
2.1 Spring force
at compressed
spring length
256.000 N
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Basic
size
lower
upper
min.
max.
min.
max.
Spring length
compressed
46.750 3
Spring length
when mod. valve
rotator is used
45.850
3.1 Spring force at
spring length
pos. 3
466.000 N 19 N +19 N Spring
force
min. 420.000 N
4 Spring length
Block dimension
42.500 Block
dimension
max. 42.500
6 Wire dia. 3.600
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Cylinder head mating surface protective sleeve
Basic
size
lower
upper
min.
max.
min.
max.
1 Cylinder head
height
184.000 0.100 +0.100 183.600
2 Protective sleeve
mating surface
124.000 0 +0.200
Protective sleeve
bore
44.200 0 +0.100 3
Protective sleeve
external
diameter
44.100 0.100 0
0.100 0.300
4 Cylinder head
and protective
sleeve thread
M 24 x 1.5
Rework only until a satisfactory mating surface has been achieved.
When reconditioning cylinder head height, reestablish the fire side contour of 13.800 +0.100.
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Basic
size
lower
upper
min.
max.
min.
max.
1 Cylinder head
screw with
engine lifting eye
333.000 0.300 +0.300
2 Cylinder head
screw
283.000 0.300 +0.300
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9.4.8 Cylinder head Repair
Special tools
Tool kit without elliptical chamfer reconditioning F6783749 1
Tool kit (accessory equipment) for elliptical chamfer reconditioning F6783751 1
Tool kit for valve-seat insert removal F6784421 1
Indexable insert F30450433 1
Mounting plate for valve guide installation F6554300 1
Valve guide extractor F30450348 1
Valve guide mandrel F6781747 1
Reamer, 19.00 mm for stage 0 cylinder head bore F30091631 1
Reamer, 19.10 mm for stage I cylinder head bore F30047578 1
Reamer, 19.30 mm for stage II cylinder head bore F30028269 1
Valve seat contour restoring tool for exhaust valve with valve-seat insert F30450631 1
Valve seat contour restoring tool for inlet valve with elliptical chamfer and
with/without valve-seat insert
F30450632 1
Turning handle for valve seat contour restoring tool 8205890451/00 1
Exhaust valve gauge Y4340443 1
Inlet valve gauge Y4340442 1
Valve seat test device Y4341935 1
Countersink reamer tool F30451554 1
Inserting mandrel for valve-seat insert, inlet F30450751 1
Inserting mandrel for valve-seat insert, exhaust F30450750 1
Material
Liquid nitrogen
Corrosion inhibitor
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Spare parts
Valve guide, inlet
Valve guide, exhaust
DANGER
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
CAUTION
CAUTION
Removing the valve-seat insert
2. Insert pilot into valve guide of cylinder head
(3) and secure.
3. Install head (2) and lathe tool on valve seat
lathe (1).
steady rest.
6. Machine valve-seat insert so that the seat insert
extractor can be installed.
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8. Install seat insert extractor (1) on the valve-seat
insert to be removed (2).
9. Using seat insert extractor (1), remove valve-seat
insert (2).
10. Check bore of valve-seat insert (1) in cylinder
head. Values ( Page 1237).
is exceeded.
Removing the valve guide
1. Place cylinder head on hydraulic press. Ensure
correct positioning of the cylinder head side.
2. Using the extractor and working from the
combustion side, press valve guide out of cylinder
head.
3. Check valve guide bore in cylinder head. Values
( Page 1237).
Result: If the value is exceeded, recondition
bore to next stage.
4. Secure cylinder head on boring mill.
5. Ream valve guide bore in cylinder head.
Installing the valve guide
1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (4) in water bath heated to
80C until cylinder head (4) has warmed up.
3. Chill valve guide (2) in liquid nitrogen for approx.
20 to 30 mins.
4. Position heated cylinder head (4) on assembly
jig (3).
5. Using mandrel (1), position chilled valve guide
(2) in bore of cylinder head (4) until the stop of
assembly jig (3) is reached.
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Installing the valve-seat insert
2. Place cylinder head in water bath heated to 80 C until cylinder head has warmed up.
3. Chill valve-seat insert in liquid nitrogen for approx. 20 to 30 mins.
4. Position heated cylinder head on suitable surface.
5. Using the inserting mandrel, install chilled valve-seat insert into the cylinder head bore until the stop is reached.
Machining the valve seat surface
2. Insert pilot (3) and support (2) into valve guide of
cylinder head (1) and secure.
3. Install suitable head (2) and lathe tool to valve
seat lathe (1).
steady rest.
Note: Note recondition dimension, required when
machining elliptical chamfer.
6. Only recondition valve seat surface until a
satisfactory surface has been established. Values
( Page 1237).
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8. Recondition valve seat surface (2) with associated
valve seat contour restoring tool (1).
9. Clean cylinder head after machining.
Checking valve seat concentricity
1. Insert pilot into valve guide.
2. Mount clamp ring (2) over inserted pilot and
secure.
3. Mount the tester (1) on clamp ring.
4. Set preloaded feeler of tester on valve seat
center (arrowed).
5. Check concentricity of valve seat in relation to
valve guide, values ( Page 1237).
Result: In event of deviation from test values,
recondition valve seat again.
6. Remove tester (1), clamp ring (2) and pilot.
Measuring valve seat depth
1. Adjust distance from plug gauge to ring gauge.
2. Set scale on dial gauge to zero.
3. Measure valve seat depth. Values ( Page 1237).
is exceeded.
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Regrinding valve seats
1. Mount valve (1) as directly as possible behind
valve head in valve grinder (2).
2. Set valve seat grinding angle on valve seat grinder.
3. Using low feed, grind valve seat only until a
satisfactory surface is achieved.
4. Measure height of outer valve seat edge as well as
valve seat width. Value ( Page 1237).
Result: If the value is not reached, replace valve.
Reconditioning elliptical chamfer (if required)
1. Insert pilot (3) for elliptical chamfer (2) into valve
guide.
2. Mount tester (1) over inserted pilot (3) and secure.
3. Set preloaded tester pointer (1) to elliptical
chamfer (2).
4. Align pilot (3) and elliptical chamfer (2) using
tester (1).
5. Secure pilot (3).
6. Remove tester (1).
7. Install suitable head and lathe tool to valve seat
lathe.
8. Position valve seat lathe on pilot and install
steady rest.
9. Set up valve seat lathe ( Page 1223).
Note: Use recondition dimension as for
machining valve seat surface.
10. Only recondition elliptical chamfer (2) until a
satisfactory surface has been achieved.
11. Check elliptical chamfer (2). Value ( Page 1237).
is exceeded.
Reconditioning the protective sleeve mating face.
1. Install countersink reamer tool in bore for protective sleeve.
2. Recondition seating surface for protective sleeve with countersink reamer tool. Value ( Page 1237).
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9.4.9 Cylinder head Plug repair
Special tools
Mandrel, 20 mm F30378617 1
Guide sleeve for mandrel F30377862 1
Mandrel, 24 mm F30271842 1
Mandrel, 30 mm F30377635 1
Material
Cleaner (Loctite 7063) 50594 1
Spare parts
Plug
Plug
Plug
WARNING
Compressed air.
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
WARNING
CAUTION
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Replacing plug
Note: Replace plug only if required.
2. Use pliers to withdraw end cover, taking care that
end cover does not fall into the bore.
3. Clean coolant chambers with cleaner
(Snow-White 11-0), then rinse with cleaner
(Hakupur 312).
4. Blow out coolant chambers with compressed air.
5. Clean mating surface of new plug and cylinder
head bore ensuring they are free of grease and dry.
6. Coat mating surface with screw locking compound.
7. Using a mandrel, knock plug into the cylinder
head bore until flush.
8. Check cylinder head for leaks ( Page 1234).
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9.4.10 Cylinder head Assembly
Special tools
Retainer 0015890321/00 1
Socket F30377634 1
Material
Engine oil
Spare parts
O-ring
Sealing ring
WARNING
Risk of injury!
WARNING
Heavy object.
CAUTION
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Installing sleeve
1. Clean sealing surface (arrow).
2. Coat O-ring (2) with grease and insert in groove
of sleeve (1).
3. Clamp cylinder head firmly.
4. Clean sealing surface of cylinder head.
5. Use torque wrench to tighten prepared sleeve
to specified tightening torque .
Sleeve Tightening torque 60 Nm +6 Nm
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Installing valves
2. Wipe valves with chamois leather and coat valve
stems with engine oil.
3. Insert valves in valve guides. Observe correct
valve arrangement. Markings are on the end
of the valve stems.
IN Inlet
EX Exhaust
4. The markings and installation positions of the
valves are located on the upper side of the
cylinder head.
IN 2 x inlet (1)
EX 2 x exhaust (2)
5. The marking is visible on the lower side of the
valve in the form of a countersink.
Inlet (1) = 20 mm
Exhaust (2) = max. 8 mm
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6. Mount supporting plate for valve spring
compressor on cylinder head.
7. Set cylinder head upright.
8. Slide valve rotator on to valve guide.
9. Fit outer and inner valve springs.
10. Fit valve spring retainers.
11. Mount valve spring compressor (2).
with valve-spring compressor (2).
13. Insert valve collets (4) in spring retainer and center.
14. Make sure that lip of valve collet fits firmly in
groove at end of stem.
15. Release valve springs.
16. After installation of all valve collets, remove valve
spring compressor (2) and mounting plate (3).
17. Place cylinder head in installation position or on
its side.
18. Make sure valves move freely.
19. Using a plastic mallet, lightly tap the valve stem to
ensure that the valve collets contact the valve
stem.
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Measuring valve clearance to cylinder head
1. Install dial gauge (2) on dial-gauge holder (1).
2. Set dial gauge (2) with preload on to plane face
of cylinder head (4).
4. Position dial-gauge stylus on valve head of
valves (3) and measure valve clearance to plane
surface.
5. If the reading is not within the tolerance
( Page 1237), check valve seat at cylinder
head and valve head.
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9.4.11 Cylinder head Installation
Special tools
Installation/removal tool for seal plug F30378956 1
Seal plug B80144872 1
Tightening tool (power amplifier) F6553658 1
Measuring tool for angle of rotation Y20044010 1
Material
Engine oil
Spare parts
Sealing ring
Gasket
WARNING
Risk of injury!
WARNING
Heavy object.
Risk of crushing!
CAUTION
CAUTION
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9
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0
Cylinder head Installation
1. Insert adjusting mandrels (2) in crankcase upper
deck.
2. Fit gasket (1).
3. Ovalize sealing ring by tapping it lightly.
4. Insert sealing ring with groove on combustion
chamber side of cylinder head.
5. When installing sealing ring, ensure position
is correct:
A = Cylinder head side
B = Piston side
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6. Remove seal plug.
7. Attach cylinder head (2) with carrying bracket (1)
and rope to crane, ensuring that the rope is
8. Place cylinder head (2) onto crankcase.
9. Coat thread, shaft and mating surfaces on heads
of cylinder head screws (1) with engine oil.
10. Observe assignment of cylinder head screws (1)
(engine lifting eye). Install cylinder head screws (1)
with thrust washers manually in crankcase.
11. Fit alignment tool (2) on inlet channels of cylinder
heads and tighten.
12. Align cylinder heads.
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A Exhaust side
B Inlet side
13. Use power amplifier and torque wrench to tighten
cylinder head screws to specified tightening torque
in accordance with the tightening sequence.
Cylinder head screw M22 x 2 Preload torque Engine oil 25 Nm
Cylinder head screw M22 x 2 Residual torque 180 Nm +10 Nm
Cylinder head screw M22 x 2 Residual angle of rotation 180 +10
Cylinder head screw M22 x 2 Control torque 400 Nm
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9.5 Valve Gear
9.5.1 Valve gear Overview
Valve gear Overview
1 Camshaft gear
3 Swing follower, inlet
4 Swing follower, exhaust
5 Camshaft
6 Pushrod
7 Shaft
8 Rocker arm, inlet
9 Nut
10 Adjusting screw
11 Rocker arm, exhaust
12 Rocker-shaft support
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9.5.2 Camshaft overview
Overview of camshaft
1 Hex screw
2 Spring washer
3 Graduated disc
4 Camshaft gear
5 Hex screw
7 Dowel pin
8 Camshaft
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9.5.3 Camshaft Removal
Preconditions
Special tools
Guide sleeve for assembly on free end F6780579 1
Centering sleeve for assembly on free end F6780582 1
WARNING
Heavy object.
Risk of crushing!
1. Remove camshaft gear as shown in overview drawing ( Page 1267).
2. To protect the crankcase from falling objects, cover equipment carrier from below.
Removing camshaft thrust bearing
2. Remove thrust bearing flange (2).
3. Check thrust bearing flange ( Page 1293).
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Camshaft Removal
1. Install inner guide sleeve (2) on face of camshaft,
free end.
2. Fasten guide flange (1) on crankcase.
3. Fasten outer guide sleeve (3) with screws (1) on
crankcase (2), driving end.
4. Screw inner guide sleeve (4), driving end, on to
camshaft.
5. Center guide sleeve to camshaft bearings.
6. Mount installation/removal tool on camshaft (2).
7. Attach camshaft with rope in middle (1) to crane.
8. Tension rope slightly and carefully withdraw
camshaft (2) horizontally from crankcase.
9. Remove guide sleeve.
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9.5.4 Camshaft Cleaning
Material
WARNING
Camshaft Cleaning
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9.5.5 Camshaft running surfaces and swing followers Visual inspection
Special tools
Spare parts
Camshaft
Roller tappet
Visually inspecting camshaft running surfaces
and swing followers
1. Remove valve drive (swing followers remain
installed) ( Page 1297).
2. Insert endoscope into crank drive through every
pushrod bore.
3. Visually check roller surface of cams, roller running
surfaces on the camshaft as well as swing
followers for damage and wear.
4. Replace swing follower if signs of corrosion are
visible, see illustrations ( Page 1297).
5. Replace camshaft if signs of corrosion are visible,
see illustrations ( Page 1285).
Install valve drive ( Page 1310).
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9.5.6 Camshaft Check
Special tools
Hardness tester DynaMIC Y20506341 1
Measuring stand 0015890321/00 1
Material
Spare parts
Camshaft
Camshaft gear
Timing wheel
Hex screw
Spring washer
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Camshaft Check
Using magnetic crack-test
procedure, check camshaft for
cracks.
Check axial bearing flange with red
dye penetrant for cracks.
Check mating face of camshaft gear. Stress marks visible Recondition: Smooth with
Replace
Check axial sliding surface, journal
faces and roller tracks of cams
for scores, stress marks and
indentations.
Scores
Stress marks
Indentations
visible
Replace camshaft.
Check tooth flank of camshaft gear
with magnifying glass.
Damaged Replace camshaft gear.
Checking hardness of cam and journal
1. Use hardness tester to check cam hardness
(inlet/exhaust rocker arms) and journals. Required
hardness: 60 HRC 2 HRC
3. Replace camshaft if values are fallen short of.
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Checking concentricity and cam lift
1. Set camshaft at outer journals on to V-blocks
(2) or roller stands.
2. Place supporting mount (3) on center journal.
3. Measure radial run-out of cam base circle
and bearings with dial gauge (1). Values
( Page 1275).
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9.5.7 Camshaft Tolerances
Concentricity of bearings
Max. permissible deviation of
concentricity
New Wear limit
During the concentricity check, provide supports for and align the following bearings.
from bearing 1 to bearing 2
0.050
a from bearing to bearing
0.025
b all cams
0.010
0.010
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Axial clearance
Basic
size
lower
upper
min.
max.
min.
max.
Wear
limit
Camshaft gear
bore
32.000
H7
0 +0.025 1
Camshaft outer
dia.
32.000
H7
0.025 0
0 0.050
2 Axial clearance 0.100 0.178
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9.5.8 Camshaft Installation
Special tools
Guide sleeve for installation/removal from free end F6780579 1
Centering sleeve for installation/removal from free end F6780582 1
Holder 0015890321/00 1
Material
Engine oil
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
CAUTION
Check camshaft ( Page 1272).
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Camshaft Installation
1. Attach outer guide sleeve (1) at driving end
of crankcase and center carefully to camshaft
bearings with inner guide sleeve (2).
2. Center guide flange (1) with guide sleeve (2) on
crankcase (free end) with regard to camshaft
bearings and secure.
3. Mount inner guide sleeve (2) on front face of
camshaft (1) and tighten.
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4. Attach camshaft (arrow) with rope at center
to crane and wipe.
5. Spray camshaft, camshaft bearing, and guide
sleeve with engine oil.
6. Install sliding block at outermost cam on camshaft.
7. Carefully insert camshaft up to second-last
bearing.
8. Position assembly extension (1) on camshaft (2)
and insert camshaft up to last bearing.
9. Locate camshaft axially and/or ensure that it
cannot fall out until thrust bearing is installed.
10. Remove inner/outer guide sleeve and assembly
extension.
Installing camshaft thrust bearing
1. Coat axial sliding surfaces with engine oil.
screws can fall into crankcase.
3. Tighten thrust bearing flange (1) with screws (2).
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swing-follower shaft, driving end.
(arrows).
Installing timing wheel (camshaft gear)
2. Install graduated disc (1) with barring tool on
crankshaft. Set to TDC mark of A1 and tighten.
3. Set piston A1 to firing TDC ( Page 1216).
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objects can fall into crankcase.
5. Insert camshaft gear (1) into camshaft so that
dowel pins (3) engage in camshaft gear bore in
a vertical line.
6. Slide timing wheel (2) over dowel pins (3) and
install.
7. Screw in screws (4) with spring washers and
tighten ( Page 980). Note position of holes of
dowel pins to screw bores.
Measuring backlash
1. Remove camshaft locating device.
3. Mount dial gauge stylus with low preload on one
tooth flank of camshaft gear.
5. Check backlash by moving camshaft gear
back and forth. Circumferential backlash
( Page 1099).
Measuring camshaft axial clearance
2. Fit dial gauge stylus on timing wheel.
3. Press camshaft on camshaft gear axially as
far as it will go.
4. Set dial gauge with preload to zero.
5. Move camshaft from stop to stop and record
measurement value (axial clearance). Axial
clearance ( Page 1275)
6. If axial clearance is out of tolerance, replace thrust
bearing ( Page 1292).
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Installing speed sensor
2. Turn speed sensor (2) slightly to install in
crankcase fit.
3. Screw in screw (1) and tighten.
Checking speed sensor clearance
1. Pull camshaft on camshaft gear axially toward free
end (arrow) as far as it will go.
2. Measure distance (X) with feeler gauge (specified
value 0.3 mm to 1 mm).
3. If distance is less than 0.3 mm:
3.1. Fit appropriate number of adjusting shims of
0.3 mm thickness.
3.2. Measure distance.
Checking camshaft timing
1. Determine TDC position of piston in the following
way:
1.1. Install measuring device (2) with dial
gauge (1) at cylinder head A1.
1.2. Fit TDC mark (graduated disc) on crankshaft
journal, free end.
1.3. Install suitable TDC pointer on equipment
carrier or crankcase, driving end.
1.4. Using the barring tool, bar the engine until
the piston of cylinder A1 is in the firing TDC.
The piston is at firing TDC when both rocker
arms are unloaded, i.e. have clearance.
2. Move piston up and down several times and then
position so that pointer on dial gauge shows its
maximum reading.
4. Rotate crankshaft against normal direction of
rotation by approx. 10.
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5. Set crankshaft in direction of rotation to 0.3 mm
(dial gauge indicator) before TDC.
6. Apply exact line marking on graduated disc, driving
end, or crankshaft journal, free end, opposite
TDC pointer tip.
7. Bar crankshaft in direction of rotation approx. 10
past TDC (to take up bearing clearance).
8. Bar crankshaft in direction opposite to normal
direction of rotation to 0.3 mm after TDC and
make a second mark. To prevent measurement
errors caused by bearing clearance, the piston
must move in direction of TDC.
9. Apply third mark at exact center between marks.
10. Align graduated disc so that mark for cylinder A1
corresponds to pointer.
11. Check TDC position.
12. Remove measuring device with dial gauge.
Measuring valve lift
1. Set cylinder A1 to firing TDC.
2. Release locknuts on adjusting screw.
3. Screw in adjusting screws until there is no longer
clearance.
4. Lightly tighten locknuts.
5. Mount magnetic-base indicator holder with dial
gauge on cylinder A1.
6. Place dial gauge stylus with slight preload on valve
bridge of inlet valve. Set scale to zero.
7. Slowly turn crankshaft further in direction of engine
rotation 360. Set to exactly overlap TDC (line
marking on graduated disc).
in Data Sheet.
9. Mount dial gauge stylus on valve bridge of exhaust
valve and set scale to zero.
10. Further rotate crankshaft slowly in engine direction
of rotation until pointer of dial gauge no longer
moves.
in Data Sheet.
12. Check that specified values are
observed. Specified values, see
DM_410_WM_000001_276A.
13. If the specified value is not attained, contact
Service.
14. Remove magnetic-base indicator holder with dial
gauge and TDC indicator.
15. Valve clearance at cylinder A1 (Operating
Instructions).
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9.5.9 Camshaft drive Overview
Camshaft drive Overview
1 Hex screw
2 Spring washer
3 Graduated disc
4 Camshaft gear
5 Hex screw
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9.5.10 Camshaft drive Removal
Special tools
1. Turn engine with barring tool in normal direction
of rotation until TDC mark and arrow on end
housing are aligned.
If rocker arms on cylinder A1 are unloaded, the
piston is in firing TDC.
If rocker arms on cylinder A1 are loaded, the
piston is in overlap TDC.
2. Remove valve drive ( Page 1297).
3. Disconnect electrical plug-in connection.
4. Remove screw (arrow).
5. Turn speed sensor (1) slightly to remove from
crankcase fit.
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swing follower shaft, driving end.
(arrows).
Removing timing wheel (camshaft gear)
2. Remove timing wheel (2) and camshaft gear (1)
from camshaft and dowel pins (3).
3. To protect the crankcase from falling objects, cover
equipment carrier from below.
4. Do not remove locating device.
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9.5.11 Camshaft drive Cleaning
Material
WARNING
Compressed air.
Risk of injury!
CAUTION
Camshaft drive Cleaning
3. Blow camshaft drive clear with compressed air.
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9.5.12 Camshaft drive Check
Spare parts
Camshaft gear
Timing wheel
Screw
Spring washer
Camshaft drive Check
Item Findings Task
Check surface condition of tooth
flanks with magnifying glass.
Scores
Stress marks
Indentations
visible
Corrective work
Replace
Check timing wheel and camshaft
gear for damage.
Replace
Check threads of hex bolts for
damage.
Damaged Replace
Check spring washer for damage. Damaged Replace
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9.5.13 Camshaft drive Installation
Special tools
Holder 0015890321/00 1
Material
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
For camshaft drive installation, see section Installing timing wheel (camshaft gear) ( Page 1277).
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9.5.14 Camshaft thrust bearing Overview
Overview of camshaft thrust bearing
1 Thrust bearing flange 2 Hex screw
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9.5.15 Camshaft thrust bearing Cleaning
Material
WARNING
WARNING
Compressed air.
Risk of injury!
CAUTION
Camshaft thrust bearing Cleaning
3. Blow thrust bearing clear with compressed air.
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9.5.16 Camshaft thrust bearing Replacement
Material
Engine oil
Spare parts
Hex screw
Camshaft thrust bearing Replacement
1. Remove camshaft drive ( Page 1285).
2. Replace camshaft thrust bearing as shown in overview drawing ( Page 1290).
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9.5.17 Camshaft thrust bearing Check
Material
Spare parts
Hex bolts
Camshaft thrust bearing Check
Item Findings Task
Test trust bearing flange for cracks
using surface crack-test method.
Check mating faces, fits and sliding
Replace
Check threads of hex bolts for ease
of movement.
Sluggish Replace
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9.5.18 Valve drive Overview
Swing follower, swing follower assembly
2 Rocker arm
3 Rocker arm
4 Precision washer
5 Snap ring
6 Hex screw
7 Washer
8 Valve bridge
9 Swing follower
10 Swing follower
12 Hex screw
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Rocker, shaft support
1 Snap ring
2 Precision washer
3 Bushing
4 Adjusting screw
6 Nut
7 Notched pin
9 Spring pin
10 Spring pin
11 Sealing plug
12 Shaft
14 Thrust element
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Swing follower
1 Bushing
2 Ball seat
5 Roller
6 Bushing
7 Bolt
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9.5.19 Valve drive Removal
Preconditions
Removing rocker arms
1. Bar crankshaft to bring piston of appropriate
cylinder to firing TDC. The piston is at firing TDC
when both rocker arms are unloaded.
Note: Ensure that no pushrod is removed by the
suction effect on the ball socket.
2. Remove screw (2) and remove rocker shaft
support (1) from cylinder head.
3. Remove valve bridges (2).
4. Pull out pushrods (1).
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Removing swing followers
2. Remove swing follower shaft with swing followers
(2) from crankcase.
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9.5.20 Valve drive Disassembly
WARNING
Risk of injury!
Disassembling rocker arms
jaws.
2. Use snap ring pliers to remove snap ring (2)
from shaft.
3. Take off washer (1).
4. Remove nut (2) and adjusting screw (3).
Removing swing follower bushing
1. Check whether the swing follower bushing must
be removed ( Page 1302).
2. If so, press out swing follower bushing (2) off swing
follower (1) using mandrel and hydraulic press.
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Removing bolt and roller
1. Check whether bolt and roller must be removed
( Page 1302).
2. If removal is required:
2.1. Position swing follower between two prisms
ensuring sufficient support at both sides
of the bolt bore.
2.2. Using mandrel and hydraulic press, remove
bolt (1) from swing follower (2).
2.3. Remove roller (3) from installation position.
Removing bushing from exhaust rocker arm
2. If so, press out rocker arm bushing (1) off exhaust
rocker arm (2) using mandrel and hydraulic press.
Removing bushing from inlet rocker arm
2. If so, press out rocker arm bushing (1) off inlet
rocker arm (2) using mandrel and hydraulic press.
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9.5.21 Valve drive Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning the valve drive
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9.5.22 Valve drive Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Holder 0015890321/00 1
Material
Crack testing oil (Nr. 63) 40475 1
Spare parts
Snap ring
Lockwasher
Bearing bushing
Swing follower
Valve bridge
Roller
Pushrod
Hex screw
Adjusting screw
CAUTION
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Checking valve drive
Item Findings Task
method, check the following
components for cracks.
Rocker shaft support and axles
Rocker arms
Valve bridges
Swing followers
Roller
Pin
Pushrods
Hex screws
Adjusting screws
Check running surfaces of axles,
rollers, valve bridges and rocker
arms for wear, indentations and
scoring.
Wear
Indentations
Scores
visible
Recondition
Replace
Check mating faces on rocker shaft
support.
Damaged Recondition
Replace
Check snap ring grooves of axles
for condition.
Damaged Recondition
Replace
Check ball element. The ball
element must not jam within the
swivel angle, on all sides at least
10, and must move freely.
Sluggish Replace
Check screws, nuts and adjusting
screws for damage.
Damaged Replace
Check pushrod concentricity. Out-of-round Replace
Measuring diameter of bushing bore in rocker arm
1. Adjust bore gauge to basic size of bushing
bore and measure diameter of bore. Values
( Page 1305).
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Measuring diameter of rocker shaft support axles
1. Using outside micrometer, measure outside
diameters of bearings. Values ( Page 1305).
2. If values are not attained, replace rocker shaft
support.
Measuring swing follower bushing bore
1. Adjust bore gauge to basic size of bushing bore
and measure diameter of bore.
Values ( Page 1305).
3. Replace gaskets and sealing washers.
4. Make sure that oil bores are perfectly clean and
free of obstruction.
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9.5.23 Valve drive Tolerances
Rocker shaft support, inlet and exhaust
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
Rocker arm bore 50.000
H7
0 +0.025 1
Bush OD 50.000
s6
+0.043 +0.059
0.018 0.059
Bush bore
installed 45.000 0 +0.050
removed 45.000
E6
+0.050 +0.066
2
f6
0.041 0.025
max.
0.100
Rocker shaft
support bore
45.000
U7
0.086 0.061 3
f6
0.041 0.025
0.020 0.061
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Swing follower support, inlet and exhaust
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Wear limit
Swing follower
bore
36.000
H7
0 +0.025 1
Bush OD 36.000
s6
+0.043 +0.059
0.018 0.059
Bush bore
installed 32.000 0 +0.050
removed 32.000
E6
+0.050 +0.066
2
Shaft OD 32.000
f6
0.041 0.025
max.
0.100
Roller bore 21.000
E7
+0.040 +0.061 3
Bush OD 21.000
H7
0.021 0
max.
0.090
Bush bore 14.000
E7
+0.032 +0.050 4
Pin OD 14.000
h5
0.008 0
max.
0.065
Swing follower
bore
14.000
P6
0.026 0.015 5
Bush OD 14.000
h5
0.008 0
0.007 0.026
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9.5.24 Valve drive Assembly
Material
Liquid nitrogen
Engine oil
DANGER
WARNING
Compressed air.
Risk of injury!
WARNING
Component is hot.
Risk of burning!
WARNING
Risk of injury!
CAUTION
Assembling rocker arm assembly
jaws.
2. Insert adjusting screw (3) into rocker arm (1).
3. Attach nut (2) to adjusting screw, do not tighten.
4. Coat axles on rocker shaft support and bushings
of rocker arms with engine oil.
5. Fit rocker arm on axle.
6. Install second rocker arm similarly.
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7. Fit washer (1) and secure with snap ring (2).
8. Check correct seating of snap ring .
9. Check minimum axial clearance of rocker arm.
Assembling inlet and exhaust swing followers
1. Chill bushings (2) in liquid nitrogen and press into
both sides of swing follower (1).
2. Observe bushing retention (A) 0.5 mm 0.5 mm.
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3. Heat swing follower to approx. 130 C to 150 C.
4. Insert roller (3) in swing follower.
5. Chill bolt (1) in liquid nitrogen. Fit in swing
follower (2) by applying hand force, ensure flush
seating. Do not press the bolt repeatedly.
Assembling rocker arm assembly
1. Chill bushing (1) in liquid nitrogen.
2. Heat exhaust rocker arm (2) to approx. 200 C.
3. Insert bushing, ensure flush seating. Projection is
not acceptable.
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9.5.25 Valve drive Installation
Special tools
Graduation plate, free end Y4341124 1
Material
Engine oil
WARNING
Compressed air.
Risk of injury!
CAUTION
Installing swing followers
1. Coat axle and bushes of swing followers with
engine oil.
2. Fit exhaust and inlet swing follower on
swing-follower shaft, ensuring they are correctly
positioned (arrows).
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3. Coat rollers and camshaft bushings with engine oil.
4. Match swing followers to left and right cylinder
banks and carefully insert into camshaft chamber.
5. Install swing-follower shaft (1) with screws.
6. Ensure correct position of installation (arrow).
Installing pushrods
1. Coat ball seats and ball sockets of pushrods
(1) with engine oil.
2. Insert pushrods (1) through cylinder head into ball
seat of swing follower.
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Installing the rocker arm
1. Release nuts (6) of adjusting screws (1) on rocker
arm (4) and back off adjusting screw (1).
2. Place rocker shaft support (4) onto cylinder head.
Take care not to damage fit of grooved pins.
3. Check position of ball joints in pushrods (5).
4. After initial assembly and after extended
out-of-service period: Fill adjusting screws (1)
with engine oil (arrow).
5. Screw hex bolt (2) with washer (3) into cylinder
head and tighten.
6. Adjust valve clearance (Operating instructions ).
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9.5.26 Cylinder head cover Overview
1 Seal
2 Cylinder head cover
3 Screw
4 Washer
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9.5.27 Cylinder head cover Removal
Cylinder head cover Removal
1. Remove screws.
2. Remove cylinder head cover and seal.
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9.5.28 Cylinder head cover Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cylinder head cover Cleaning
1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then flush with cleaning agent (Hakupur 312).
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9.5.29 Cylinder head cover Check
Special tools
Oilstone 8205893261/00 1
Spare parts
Cylinder head cover
Screw
Checking the cylinder head cover
Check cylinder head cover for
damage.
Damaged Corrective work: Smoothen
with emery cloth or oilstone.
Replace
Check threads of screws for ease of
movement.
Replace
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9.5.30 Cylinder head cover Installation
Material
Engine oil
Spare parts
Seal
Screw
Washer
CAUTION
Cylinder head cover Installation
1. Install cylinder head cover with seal.
2. Tighten screws.
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9.6 High Pressure Fuel System
9.6.1 HP fuel system Overview
1 Injector
2 HP fuel line
3 HP accumulator
5 HP fuel line, left engine side
6 HP fuel pump
7 HP fuel line, right engine side
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9.6.2 HP pump Overview
1 HP pump
2 Screw
3 Washer
4 Washer
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Front view of HP pump
1 HP line to right-hand engine side
3 HP line to left-hand engine side
4 HP sensor
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9.6.3 HP pump Removal
Special tools
Hot-air gun 0005388520 1
WARNING
Do not smoke.
WARNING
Heavy object.
Risk of crushing!
WARNING
Component is hot.
Risk of burning!
HP pump Removal
3. Remove HP pump (1).
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6. Heat intermediate piece (2) to approx. 130C to
free up screw locking compound.
7. Remove intermediate piece (2).
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9.6.4 High-pressure pump Disassembly
This assembly is a replacement part (Reman). It is available within the scope of the service-exchange scheme.
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9.6.5 High-pressure pump Check
Spare parts
High-pressure pump
Screw
High-pressure pump Check
Item Findings Task
Check connection thread on
high-pressure pump for damage.
No ease of movement Recondition
Replace
Check drive gear for damage. Damaged Replace high-pressure pump.
Check wiring for damage. Damaged Replace wiring.
Check sealing faces for damage. Damaged Recondition
Replace
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9.6.6 HP pump Installation
Special tools
Material
Engine oil
Spare parts
O-ring
DANGER
Suspended load.
Danger to life!
CAUTION
CAUTION
HP pump Installation
2. Coat thread of intermediate piece (3) with screw
locking compound.
3. Screw intermediate piece (3) into shaft (2).
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6. Insert HP pump (1) into bore.
7. Insert screws (2) and tighten.
8. Remove lifting equipment from HP pump.
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9.6.7 H.P. fuel pump Control block replacement
Preconditions
Special tools
Material
Engine oil
Spare parts
Control block
O-ring
Connector
WARNING
Do not smoke.
Removing control block
1. Remove fuel line (5) from control block (4). Collect
emerging fuel.
connector (6) from magnet.
connector (1) from sensor.
4. Remove sensor (1).
5. Remove screws (3) from control block (4).
6. Remove control block (4) from H.P. fuel pump (7).
Installing control block
1. Coat O-ring with engine oil and insert into groove.
2. Screw control unit (4) with screws (3) onto H.P. fuel pump (7) and tighten to specified torque ( Page 980) .
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3. Connect connector (6) to magnet and tighten bayonet lock using pliers.
5. Screw sensor (1) into bore by hand.
6. Tighten nut (2) with torque wrench to specified tightening torque ( Page 980) .
7. Connect connector to sensor (1) and tighten bayonet lock using pliers.
8. Attach fuel line (5) to control block (4).
9. Vent fuel lines.
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9.6.8 Injector Overview
Injector Overview
1 Hold-down clamp
2 Hex screw
3 O-ring
4 Injector
5 O-ring
6 CE-ring
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9.6.9 Injector Removal
Special tools
Puller F30377769 1
Puller bracket F6557991 1
WARNING
Do not smoke.
Remove injector
1. Remove H.P. line (2).
2. Remove screw (1) from hold-down clamp (2).
3. Take off hold-down clamp.
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4. Place puller (4) on injector (1).
5. Turn locking sleeve (2) of puller (1) from position
"a" to position "b".
6. Secure locking sleeve with nut.
7. Place puller bracket (2) on cylinder head.
8. Screw in threaded rod (3) in puller (5).
9. Secure nuts (4).
10. Withdraw fuel injector by turning nut (1) to the right.
11. Remove special tool.
12. Remove puller bracket and locking sleeve.
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13. Remove fuel injector.
14. Remove O-rings (2) from injector.
15. Remove sealing ring (1) from injector or use wire
hook to remove from cylinder head.
16. Seal all connections and installation bores with
covers or plugs.
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9.6.10 Fuel injector disassembly
This component is an exchange component (Reman) and is available through the usual exchange procedure.
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9.6.11 Injector Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
WARNING
CAUTION
Injector Cleaning
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9.6.12 Injector Check
Material
Crack testing oil (NR. 63) 40475 1
Spare parts
Fuel injector
Hold-down clamp
Screw
Check injector
Inspect fuel injector externally for
damage.
Damaged Replace
Check screws and hold-down
clamp for cracks with magnetic
Indication of cracks Replace
Check contact surfaces of hold-down
clamp.
Damaged Rework: smooth with oilstone.
Replace
Inspect sealing cone of fuel injector
for damage.
Damaged Replace injector.
Check cable connections for
damage.
Damaged Replace wiring harness.
Check thread on screw and injector
valve for ease of movement.
Sluggish Rework
Replace
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9.6.13 Injector Installation
Special tools
Lever F6555197 1
Force-in lever F6557952 1
Material
Engine oil
Grease (Retinax EP2) 40388 1
Spare parts
O-rings
Sealing ring
WARNING
Do not smoke.
Check injector ( Page 1335).
Injector Installation
2. Fit O-rings on fuel injector.
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3. Use Retinax EP2 grease to fit sealing ring on
mating face of injector.
4. Fit sealing ring on injector so that the even contact
surface faces injector.
5. Insert fuel injector (1) in cylinder head. Ensure
that injector is correctly aligned with H.P. fuel
line connection.
6. Fit force-in tool (2).
7. Lock force-in lever (1) of forces-in tool between
the pushrods.
8. Release palm grip (3) and move pressure element
(2) to correct position for force-in tool.
9. Secure palm grip and press injector (4) with
force-in lever into cylinder head.
10. Remove force-in tool.
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11. Fit hold-down clamp (2) in correct position by hand.
Note: Tighten screw of hold-down clamp only
after connecting the H.P. line.
12. Hand-tighten screw (1) so that the injector is
still rotatable.
13. Install H.P. lines between connecting piece and
injector ( Page 1354).
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9.6.14 High-pressure line Overview
HP line from HP accumulator to injector
1 Hold-down clamp
2 Cable connection
3 Injector
4 Filter element
5 Fuel return line
6 HP line
8 Limiting valve
9 HP accumulator
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HP line from HP pump to HP accumulator
1 HP line, left side
2 HP line, right side
3 Retainer
4 Pipe half-clamp
5 Screw
6 Retainer
7 Pipe half-clamp
8 Screw
9 Grommet
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HP accumulator and add-on components
1 HP accumulator
2 Thrust element
3 Thrust element
4 Thrust screw
5 O-ring
7 Adapter
8 Thrust screw
9 Connecting piece
10 Screw
11 Limiting valve
12 HP line
13 O-ring
14 Plug-in pipe
15 Sealing ring
16 Plug
17 Plug-in pipe
18 Plug-in pipe
19 Plug-in pipe
20 Plug-in pipe
21 Screw
22 Washer
23 O-ring
24 O-ring
25 O-ring
26 Snap ring
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HP accumulator, left engine side
1 O-ring
2 Thrust screw
3 Thrust element
5 Telltale bore
6 Plug-in pipe
7 Thrust element
8 Screw
9 Thrust element
10 Plug-in pipe
12 HP accumulator
13 O-ring
14 Plug-in pipe
HP accumulator, right engine side
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1 Screw
3 Plug-in pipe
5 O-ring
6 Telltale bore
7 Plug-in pipe
8 HP line
9 O-ring
10 Thrust screw
11 Thrust element
12 HP accumulator
14 Plug-in pipe
15 Thrust element
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9.6.15 HP fuel line Removal
Special tools
WARNING
Do not smoke.
Removing HP line between HP pump and HP accumulator
Note: Prior to removing HP lines, it is advisable to take photographs of all fitted lines or to identify lines
with metal tags.
1. Release threaded union on HP lines and catch fuel emerging.
2. Remove HP fuel lines as per overview drawings ( Page 1339).
3. After removal of the lines, seal all connections with suitable plugs.
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Removing HP fuel lines
accumulator on injector side (arrow).
accumulator on HP accumulator side (arrow).
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Removing HP accumulator
1. Remove fuel return line (1) on HP accumulator of
right engine side, driving end.
2. Remove pressure relief valve.
3. Withdraw plug-in pipe end section (2) and remove
O-ring.
4. Remove limiting valves (2) from connecting
pieces (3).
5. Withdraw plug-in pipe end section (1) from left HP
accumulator.
6. Carefully remove HP accumulator from connecting
pieces and plug-in pipes.
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7. Remove screws (4) from connecting piece (2)
and take off together with plug-in pipe (1) from
crankcase.
8. Remove O-ring (3) from connecting pieces.
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9.6.16 HP fuel line Disassembly
Special tools
WARNING
Heavy object.
Risk of crushing!
Remove HP fuel line ( Page 1344).
Disassembling HP accumulator
1. Use retaining device (arrow) to clamp HP
2. Unscrew thrust screw.
3. Remove thrust pad and pressure relief valve.
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9.6.17 HP fuel line Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
HP fuel line Cleaning
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9.6.18 H.P. fuel line Check
Material
Fluorescent magnetic powder for magnetic crack-testing procedure
Spare parts
H.P. accumulator
Pressure-relief valve
Plug-in pipe
Thrust pad
Limiting valve
Disassemble H.P. fuel line ( Page 1348).
H.P. fuel line Check
Item Findings Task
method, check H.P. accumulator for
cracks.
Signs of cracks Replace pressure accumulator.
Check all threads for ease of
movement.
Sluggish Recondition: recut threads.
Replace
Check sealing tapers on thrust pads
for damage.
Damaged Replace
Check sealing cone of pressure
accumulator for damage and wear.
Damage
Wear
visible
Replace
Check that H.P. lines, plug-in pipes
and fuel return line are in perfect
condition.
Damaged Recondition
Replace
Check that H.P. lines and H.P.
accumulator are perfectly clean.
Contaminated Clean ( Page 1349)
For checking limiting valves
and pressure relief valves, see
Manufacturers Documentation.
Damaged Contact Service.
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9.6.19 HP fuel line Assembly
Special tools
Material
Molykote G-n plus 40041 1
Engine oil
Spare parts
O-ring
Snap ring
Sealing ring
Washer
A Thrust element with thrust ring (X = 15.5 mm)
B Thrust element without thrust ring (Y = 23.5 mm)
Thrust element, alternatives A and B
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Pressing on thrust ring - Variant A only
1. Degrease and dry thrust element surfaces.
2. Coat surface (arrowed) with oil.
3. Press-fit thrust ring (2) with supporting washer (3)
on thrust element (1).
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Assembling HP fuel line, alternatives A and B
1. Coat mating surfaces between thrust screw and
thrust element as well as between thrust screw
and adapter with Molykote G-n plus.
2. Push thrust screw (1) onto thrust element (2).
3. Coat threads (arrowed) and taper (arrowed)
with engine oil.
4. Preassemble HP accumulator:
4.1. Use retaining device to clamp HP
4.2. Insert prepared thrust pieces with thrust
screws as well as adapter and thrust screw
for pressure-relief valve ( Page 1339)in
seating bore and tighten with torque
wrench to the specified tightening torque
( Page 980).
4.3. Install pressure relief valve, and insert but
do not tighten socket-head screws.
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9.6.20 HP fuel line Installation
Special tools
Alignment tool for HP accumulator F6557185 2
Slotted nut screwdriver F30379005 1
Material
Engine oil
Spare parts
O-ring
Gasket
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
CAUTION
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Preparing connecting pieces
2. Insert O-rings in grooves (arrowed) on connecting
piece.
Installing HP accumulator on crankcase
1. Fit connecting pieces and plug-in pipes together in
alternating sequence.
Note: Align plug-in pipes with leak check outlet
facing downwards
2. Fit plug-in pipes over connecting piece O-rings.
3. Insert screws (arrows) for attaching the connecting
piece to the crankcase.
4. Insert HP accumulator in preassembled connecting
piece and plug-in pipe assembly.
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5. Insert alignment tools in tightened connecting
pieces (first and last connecting piece of respective
engine side).
6. Align HP accumulator until alignment tool taper is
centered in bore of HP accumulator.
7. Tighten alignment tool to 20 Nm +2 Nm.
8. Insert limiting valve into outlet openings (arrowed)
of all connecting pieces.
9. If injectors have been removed, they must be
installed first ( Page 1336).
10. Using a slotted nut screwdriver, tighten thrust rings
(2) at the thread end to 10 Nm.
Result: Distance of pipe end to thrust ring A =
11.7 mm.
11. Coat O-rings with grease and insert in grooves.
12. Pretighten HP lines between limiting valve and
injector to 5 to 10 Nm.
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13. Use torque wrench to fasten HP lines to the limiting
valves (2) and tighten to specified tightening
torque ( Page 980).
14. Use torque wrench to fasten HP lines to the
injectors (1) and tighten to specified tightening
torque ( Page 980).
16. Insert remaining limiting valves and tighten HP
lines as described.
17. Use torque wrench to tighten hold-down clamp with
screw to specified tightening torque ( Page 980).
18. Use torque wrench to tighten all screws for
attaching connecting pieces to the crankcase to
19. Complete HP accumulator ( Page 1339).
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21. Coat thread and screw heads (3) with oil.
22. Install pressure relief valve (2) and fit screws (3)
evenly by hand.
23. Install return line (1) between fuel collecting line
and pressure relief valve.
24. Pressure relief valve:
Variant A
Use torque wrench to tighten 3 screws (3) to
Variant B
Tighten 6 screws (3), spherical washers and
conical sockets crosswise in stages to specified
Installing HP line between HP pump and HP accumulator
1. Blow out HP lines with compressed air.
2. Install HP lines and securing hardware as per overview drawing ( Page 1339) or according to
photos/markings, ensuring that the connections are free of tension.
3. Leak test fuel system (high-pressure) ( Page 1359).
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9.6.21 H.P. fuel system Leak check
WARNING
Compressed air.
Risk of injury!
Checking common rail system for leaks
1. Remove pressure sensor (1) from high-pressure
pump (2).
2. Install H.P. inspection line and apply pressure to
system. Test pressure: 3 bar
4. Check all threaded connections in system for leaks.
5. Again remove H.P. testing line from high-pressure
pump.
6. Insert pressure sensor on H.P. pump and tighten to
specified torque with torque wrench (Page 980) .
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9.7 Low Pressure Fuel System
9.7.1 Fuel system Overview
Fuel system
1 Fuel service tank
2 Non-return flap
3 Fuel prefilter
4 Fuel delivery pump, electric
motor drive
5 Non-return flap
7 Connection, fuel supply to engine
8 Fuel hand pump
9 Fuel delivery pump with pressure
relief valve
11 Connection, fuel return from engine
after filter
after H.P. pump
14 Measuring point, fuel temperature
after fuel H.P. pump
15 Jacketed pipe
16 Connection, leak-off fuel return
from jacketed fuel line
17 H.P. accumulator
18 pressure relief valve
19 Injector
20 H.P. fuel pump
21 Connection, return from fuel
prefilter
22 Connection, supply to fuel prefilter
23 Fuel filter
24 Non-return valve after fuel
delivery pump
25 Fuel ventilation
26 Fuel restrictor
from engine
from engine
29 Connection for leak-off fuel return
30 Leak-off fuel tank
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Fuel delivery pump Overview
2 Coupling element
3 O-ring
4 Hex bolt
5 Washer
6 Hex bolt
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Preconditions
WARNING
Do not smoke.
Removing fuel delivery pump
1. Remove fuel delivery pump as per overview drawing ( Page 1361).
2. Remove coupling element from the drive shaft of the fuel delivery pump.
3. Remove O-ring.
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9.7.4 Fuel delivery pump Disassembly
Disassembling fuel delivery pump
In the event of wear or a complaint, the fuel delivery pump must be replaced.
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Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
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9.7.6 Fuel delivery pump Check
Spare parts
Fuel delivery pump
Screw
Coupling
WARNING
Do not smoke.
Fuel delivery pump Check
Item Findings Task
Perform external check of fuel
delivery pump for perfect condition.
Damaged Replace fuel delivery pump
Check coupling for stress marks and
damage.
Damaged Replace coupling
Check driver of pump shaft for wear. Damaged Recondition: Smooth with
Refer to manufacturers
documentation when replacing
the driver.
Check threads of securing screws. Damaged Replace
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Material
Engine oil
Spare parts
O-ring
WARNING
Do not smoke.
2. Mount coupling element (2) on driver.
3. Align fuel delivery pump driver to coupling element.
4. Carefully insert fuel delivery pump in bore
and install as shown in overview drawing
( Page 1361).
5. If the pump cannot be inserted up to the stop,
remove the pump again and check the position of
the driver to the coupling element.
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WARNING
Do not smoke.
Fuel delivery pump Removal
1. Switch off fuel delivery pump and disconnect from power supply.
2. Remove fuel lines.
3. Collect emerging fuel in a suitable container.
4. Remove securing screws from fuel delivery pump.
5. Remove fuel delivery pump.
6. Seal all openings on the engine.
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Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
CAUTION
1. Clean all components using cleaning agent.
3. Blow off all parts thoroughly with compressed air.
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WARNING
Do not smoke.
Clean fuel delivery pump ( Page 1369).
1. Open connections on engine.
2. Mount fuel delivery pump on foundation with securing screws.
3. Install fuel lines.
4. Connect fuel delivery pump to power supply.
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9.7.12 Fuel pipework from fuel delivery pump to fuel filter Overview
1 Plug-in pipe
2 O-ring
3 Flange
4 Non-return valve
5 O-ring
6 O-ring
7 Screw
8 Washer
9 Plug-in pipe
10 O-ring
11 Flange
12 Flange
13 O-ring
14 Screw
15 Washer
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9.7.13 Fuel lines from fuel delivery pump to fuel filter Removal
Preconditions
WARNING
Do not smoke.
Removing fuel lines from fuel delivery pump to fuel filter
2. Disconnect fuel line and collect escaping fuel.
3. Remove fuel lines from fuel delivery pump to fuel filter as shown in overview drawing ( Page 1371).
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9.7.14 Fuel lines from pump to filter Cleaning
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove fuel lines ( Page 1372).
Cleaning fuel lines
1. Clean fuel lines and non-return valve with cleaning agent.
3. Thoroughly blow out fuel lines and non-return valve with compressed air.
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9.7.15 Fuel lines from fuel delivery pump to fuel filter Check
Spare parts
Non-return valve
Flange
Plug-in pipe
WARNING
Risk of injury!
Fuel lines from fuel delivery pump to fuel filter Check
Item Findings Task
Visually check plug-in pipes, flanges and
non-return valve for damage and wear.
Damaged Replace
Check plug-in pipes for leaks with air
in water bath as necessary. A water
temperature of min = 30 C or max = 40 C
and a test pressure of 0.5 bar must be
maintained.
Leaking Replace
Check non-return valve for leaks and
check opening pressure.
Leaking
Opening pressure
incorrect.
Replace
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9.7.16 Fuel lines from fuel delivery pump to fuel filter Installation
Material
Spare parts
O-ring
WARNING
Do not smoke.
CAUTION
Fuel lines from fuel delivery pump to fuel filter Installation
2. Install O-rings on plug-in pipes and coat with grease.
3. Install fuel lines as per overview drawing ( Page 1371).
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9.7.17 Fuel duplex filter Overview
1 Valve (0.5 bar)
2 Plug screw
3 Plug screw
4 Valve (1 bar)
5 Plug screw
6 Threaded union
7 Fuel line
8 Plug screw
9 Screw
10 O-ring
11 Fuel hand pump
12 Plug screw
13 Threaded union
14 Blanking cone
15 Nut
16 O-ring
17 Elbow
18 Screw
19 Threaded nipple
20 Easy-change fuel filter
21 Threaded nipple
22 Plug screw
23 Plug screw
24 Filter head
25 Threaded union
26 Blanking cone
27 Nut
28 Threaded union
29 Threaded union
30 O-ring
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9.7.18 Fuel duplex filter Removal
Preconditions
Special tools
WARNING
Do not smoke.
Fuel duplex filter Removal
1. Remove filter elements using filter wrench (1).
3. Remove filter head as shown in overview drawing
( Page 1376).
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9.7.19 Fuel duplex filter Disassembly
WARNING
Do not smoke.
Fuel duplex filter Disassembly
1. Remove and disassemble hand pump as shown in overview drawing ( Page 1376).
2. Disassemble filter head as shown in overview drawing.
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9.7.20 Fuel filter Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Fuel filter Cleaning
3. Thoroughly blow out all parts using compressed air.
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9.7.21 Fuel filter Check
WARNING
Risk of injury!
Checking fuel filter
Visually inspect filter head and hand
pump for damage and condition
Damaged Replace
damage
Damaged Smooth with oilstone
Replace
holes.
Damaged Rework: recut thread.
Replace
Leak-test filter head using air and
water bath. Install filter elements
before carrying out leak test. Test
temperature: min. 30 C, max.
40 C, if oil filter housing has to be
held in hands. Test pressure: 0.5
bar.
Leaking Replace plugs and sealing
rings
Replace filter head
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9.7.22 Fuel duplex filter Assembly
Material
Engine oil
Spare parts
Plug screw
O-ring
WARNING
Do not smoke.
Fuel duplex filter Assembly
Note: Coat O-rings with grease.
1. Assemble filter head as shown in overview drawing ( Page 1376).
2. Assemble hand pump as shown in overview drawing and install on filter head ( Page 1376).
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9.7.23 Fuel duplex filter Installation
Material
WARNING
Do not smoke.
Installing fuel duplex filter
3. Install fuel duplex filter as shown in overview drawing ( Page 1376).
Installing easy-change fuel filter
1. Coat sealing rings (arrow) of filters with fuel.
2. Install filter and tighten by hand.
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9.7.24 Fuel pipework from fuel filter to HP pump Overview
Fuel line
1 Fuel line
2 Union
3 Pipe half-clamp
4 Pipe half-clamp
5 Grommet
6 Washer
7 Screw
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9.7.25 Fuel pipework from fuel filter to HP pump Removal
Preconditions
WARNING
Do not smoke.
Fuel pipework from fuel filter to HP pump Removal
2. Remove fuel line with securing hardware as shown in overview drawing ( Page 1383).
3. After removal of the fuel lines, seal all connections with suitable plugs.
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9.7.26 Fuel pipework from fuel filter to high-pressure pump Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Fuel pipework from fuel filter to high-pressure pump Cleaning
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9.7.27 Fuel pipework from fuel filter to high-pressure pump Check
Spare parts
Fuel line
Retainer
WARNING
Risk of injury!
Fuel pipework from fuel filter to high-pressure pump Check
Item Findings Task
Visually inspect fuel lines for
damage.
Replace
Pressure-test fuel line with air
in water bath for leaks. A water
temperature of min. = 30 C or
max. = 40 C and a test pressure of
Leaking Replace
damage.
oilstone.
Replace
Check threads of union nuts
and threaded unions for ease of
movement.
Replace
Check securing elements on fuel
lines for damage.
Damaged Replace
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9.7.28 Fuel pipework from fuel filter to HP pump Installation
Material
Engine oil
Spare parts
Grommet
WARNING
Do not smoke.
CAUTION
CAUTION
Fuel pipework from fuel filter to HP pump Installation
2. Install fuel pipework from fuel filter to HP pump as per overview drawing ( Page 1383).
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9.7.29 Leak-off fuel pipework Overview
Fuel return lines
1 Fuel return line
2 Union
3 Sealing ring
6 Union
7 Sealing ring
8 Sealing cone
9 Plug nut
10 Pipe half-clamp
11 Screw
12 Grommet
13 Retainer
14 Grommet
15 Grommet
16 Screw
17 Screw
18 Pipe half-clamp
19 Pipe half-clamp
20 Fuel return line
21 Fuel return line
22 Fuel return line
23 Fuel return line
24 Banjo screw
25 Sealing ring
26 T adapter
27 Fuel return line
28 Fuel return line
29 Grommet
30 Grommet
31 Pipe half-clamp
32 Pipe half-clamp
33 Screw
34 Pipe half-clamp
35 Union
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1 Leak-off fuel housing
2 Screw
3 Washer
4 Adapter
5 Union
6 Sealing ring
7 Plug screw
10 Threaded adapter
11 Sealing ring
12 Sealing cone
13 Nut
14 Retainer
15 Retainer
16 Grommet
17 Pipe half-clamp
18 Pipe half-clamp
19 Screw
20 Pipe half-clamp
21 Pipe half-clamp
22 Screw
23 Grommet
24 Screw
25 Pipe half-clamp
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9.7.30 Leak-off fuel line Removal
Preconditions
WARNING
Do not smoke.
Removing leak-off fuel line
1. Prior to removal of the lines take photos or mark add-on components and lines.
3. Remove fuel lines with securing hardware as per overview drawing ( Page 1388).
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9.7.31 Leak-off fuel pipework Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Leak-off fuel pipework Cleaning
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9.7.32 Leak-off fuel pipework Check
Spare parts
Sealing rings
WARNING
Risk of injury!
Leak-off fuel pipework Check
Item Findings Task
Visually inspect all leak-off fuel lines
for damage.
Replace
Pressure-test leak-off fuel lines with
air in water bath for leaks. A water
temperature of min = 30C and
max = 40C and a test pressure of
Leaking Replace
Damaged
Threads sluggish.
Corrective work: Recut threads
Replace
damage
oilstone.
Replace
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9.7.33 Leak-off fuel line Installation
Spare parts
Sealing ring
Grommet
WARNING
Do not smoke.
CAUTION
CAUTION
Installing leak-off fuel line
2. Install leak-off fuel line according to overview drawing ( Page 1388) or according to photos/markings.
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9.8 Exhaust Turbocharger
9.8.1 Exhaust turbochargers Overview
Exhaust turbochargers Overview
engine side
engine side
13 Locking plate
14 Adapter
16 Screw
18 Screw
19 Washer
25 Nut
30 Sealing ring
35 Screw
40 Spacer sleeve
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9.8.2 Exhaust turbocharger Removal
Preconditions
Special tools
WARNING
Heavy object.
Risk of crushing!
Exhaust turbocharger Removal
1. Insert eyebolt into bearing housing of exhaust turbocharger.
2. Secure exhaust turbocharger with crane and hook-ended chain sling.
3. Remove nuts and sleeves for exhaust turbocharger as per overview drawing ( Page 1394).
4. Remove exhaust turbocharger from exhaust manifold.
6. Remove studs from exhaust manifold.
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9.8.3 Exhaust turbocharger Disassembly
Special tools
Vibe jaw F70144375 2
T torque wrench F30520703 1
WARNING
WARNING
Risk of injury!
Exhaust turbocharger Disassembly
1. Mark positions of compressor casing (1) and
turbine housing (4) to the bearing housing (2) and
to the back wall of the compressor (arrows).
2. Mount turbine housing (4) on the gas intake
flange with braces.
3. Remove tensioning segments (3) from turbine
housing.
4. Carefully take turbine housing (4) off bearing
housing, in doing so do not tilt housing. Tilting
can cause damage to the blade.
5. If the turbine housing (4) sticks, use rust-removing
agent. If necessary, use copper hammer.
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6. Remove nuts (1) and tensioning segments (2) from
compressor casing.
7. Carefully take compressor casing off bearing
housing. Take care that the blade is not damaged.
8. If the turbine housing sticks, use a rubber mallet.
9. Mount impeller on the hub in the vibe jaw (3).
Note: Left-hand thread
10. Remove self-locking nut (2) with two-armed
wrench (1).
11. The nut is only loosened with the two-armed
wrench so that the impeller shaft is not damaged.
12. Pull compressor wheel (1) off compressor shaft, if
necessary press the impeller out with a handpress
(arrow).
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13. Carefully remove impeller shaft (2) from bearing
housing (1).
14. Center heat shield (3) and remove from the
impeller shaft, in doing so observe piston rings.
impeller shaft.
16. Mount bearing housing between both flange faces
in bench vise (use braces).
17. Remove screws (1), take back wall (2) off bearing
housing and remove O-rings.
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18. Press sealing bushing (1) out of back wall (3).
sealing bushing (1).
20. Remove oil thrower ring (1), oil retainer (2), bearing
collar (3), axial bearing washer (6), bushing (5)
and bearing collar (4) from bearing housing.
21. Install snap rings (1) and bearing bushing (2) at
the compressor side and then remove snap rings
(3) and bearing bushing (4) at the turbine side.
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9.8.4 Exhaust turbocharger Cleaning
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
WARNING
Do not smoke.
CAUTION
Disassemble exhaust turbocharger ( Page 1396).
Exhaust turbocharger Cleaning
3. Thoroughly blow off all parts with compressed air.
Wet sand blasting
1. Protect bearing bores and piston ring sealing faces on the bearing housing and shaft and piston ring sealing
faces on the back wall from cast-steel shots.
2. Wet sand blast housing, impeller, compressor wheel, back wall and heat shield.
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9.8.5 Exhaust turbocharger Check
Spare parts
Bearing housing
Turbine housing
Compressor housing
Rotor
Compressor wheel
Exhaust turbocharger check
Visually check housing, guide vane
ring, heat shield and impellers for
cracks, foreign objects and scoring.
Cracks
Foreign objects
Scoring
visible
Replace
Check oil supply bores in bearing
housing for foreign objects.
Foreign objects visible. Replace
Check piston sealing faces and
bearing points for damage.
Damaged Replace
Check turbine housing for scaling. Scale visible on gas inlet land or
circumference.
Replace
Check gas inlet flange and gas
outlet flange for flatness.
Flange uneven. Corrective work: Smooth using
oilstone.
Replace
Check impellers for bent or broken
blades and check impeller shaft for
scored bearings.
Damaged Replace
Check piston seat in rear wall and
bearing housing for scoring and
damage.
Scores
Damage
visible
Replace
Self-locking nuts
O-rings
Replace
Wear parts and rotating parts that display cracks must be replaced.
Replace clamping segments, nut, shaft nut, piston rings, cylinder head bolts and washers, O-rings, oil deflector,
thrust washer, snap rings, bearing bushings and screws during overhaul.
Bearing housing
Note: The segment mating faces must not display severe corrosion.
1. Measure max. bore ID at the bearing points using a bore gauge.
Max. bore ID = 22.272 mm
2. If the limit value is exceeded, replace bearing housing.
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Turbine housing
1. Radial cracks of up to 10 mm in length in the area
of lug (2) and partition wall (1) are permissible.
2. Complete cracking is not permissible.
3. Slight scoring in the circumferential area is
permissible.
4. Replace component if the gas inlet flange or gas
outlet flange is distorted.
Compressor housing
1. Check circumferential area (arrowed) for scoring
and deformation. Scoring of up to 0.2 mm
is permissible.
2. Replace compressor housing if deformed.
Rotor
1. Check rotor shaft for roundness:
1.1. Position rotor shaft on two V-blocks at
the bearing points.
1.2. Position measuring sensor on the shaft
at a distance of 5 mm to the end of the
compressor wheel seat.
1.3. Evenly press rotor shaft onto the V-blocks
during testing.
1.4. Maximum permissible radial runout <
0.008 mm.
1.5. Replace rotor if the permissible radial
runout is exceeded.
2. Measure shaft diameter at the bearing points and
piston ring groove width.
Min. diameter = 14.25 mm
Max. groove width = 3.32 mm
3. Replace shaft if limit values are violated.
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Note: During production, all compressor wheels and
shafts are balanced separately. Deposits and
contamination on the compressor and turbine
wheels can lead to unbalance during operation.
Unless a new rotor assembly is installed,
the entire rotor assembly must be balanced
during each repair.
Balancing rotor assembly
1. Clean all parts of the rotor assembly (rotors,
bearing collar, seal bushing (oil deflector ring),
bush, compressor wheel and shaft nut) prior
to balancing.
2. The position of the parts relative to each other
must be marked.
Note: The rotor assembly must only be balanced
in planes A and B!
3. Support rotor assembly at bearing points (arrowed)
in balancing device.
4. Impermissible residual unbalance of the rotor
assembly must be reduced by taking off material
(see following paragraphs) in planes A and B to
the max. values stated in the table.
Turbocharger type Balancing plane A (C) in mmg Balancing plane B (T) in mmg
K 36 4.0 3.1
K 37 4.6 3.6
Removing material at compressor wheel
1. During material removal in the area of the blade
base a minimum distance (X) of 2 mm must
be adhered to.
surrounding area.
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Removing material at turbine wheel
1. Material removal during balancing in a circle
segment of max. 150.
surrounding area.
Max. permissible material removal
Turbocharger
type
Compressor wheel Turbine wheel
D
(mm)
R
(mm)
F
(mm)
G
(mm)
H
(mm)
K 36 4 4 2.5 4.0 1.5
K 37 4 5 2.5 4.0 1.5
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9.8.6 Exhaust turbocharger Tolerances
B Compressor wheel rear side


bearings
0.58

bearings
0.68
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B Compressor wheel rear side 0.8


bearings
0.57

bearings
0.72
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9.8.7 Exhaust turbocharger Assembly
Special tools
Assembly jaws F70144375 2.
Tee torque wrench, 10-90 Nm F30520703 1
Angle of rotation measuring device Y20044010 1
Dynamometer Y20504961 1
Material
Engine oil 40453 1
Assembly paste Ultra-Therm MTU 50547 1
Loctite 640 40105 1
Spare parts
O-rings
Spring pins
Piston rings
Bearing bushings
Piston rings
Snap ring
WARNING
Heavy object.
Risk of crushing!
WARNING
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Exhaust turbocharger Assembly
1. Check that all parts are perfectly clean, clean if
required.
2. Oil the following bearing components prior
to installation:
Rotor bearing seats
Bearing bushings
Thrust washer
Sealing bushing
Oil control ring
Bearing collar
Piston rings
Bushing
3. Install snap rings (1) and bearing bushing (2) from
compressor side, then snap rings (3) and bearing
bushing (4) from turbine side in bearing housing.
4. Insert snap rings with the round edge facing the
bearing bushing. Ensure that the snap ring is
properly seated in the groove!
5. Clamp rotor shaft in bench vise (use protective
jaws).
6. Carefully fit piston rings (1) on shaft, aligning the
piston ring joints (arrow) arranged with an offset
of 180.
7. Center piston rings on rotor shaft.
8. Carefully place heat shield (1) over piston rings on
turbine wheel.
9. Insert a sheet strip (2) of 1 mm thickness between
heat shield and rear side of turbine wheel to
ensure that the piston rings are properly guided in
the bearing housing bore.
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10. If the rotor assembly has been rebalanced,
observe the associated position markings.
11. Move sleeve onto rotor shaft to protect the thread.
12. Carefully move bearing housing (4) onto rotor
shaft, ensuring that the oil supply bore of the
bearing housing is arranged with an offset of 90
towards the piston ring joint.
Note: The piston rings are properly seated when
heat shield and bearing housing can
easily be rotated.
13. Move first bearing collar (5) and bushing (2)
onto rotor shaft.
14. Insert thrust washer (3) in bearing housing,
ensuring that the centering pins (arrows) are
properly seated.
15. Move second bearing collar (1) onto rotor shaft.
16. Place oil baffle plate (1) on thrust washer, ensuring
that the oil baffle plate is properly seated (arrows).
17. Move oil control ring (3) with smaller collar facing
downwards onto rotor shaft.
in groove in bearing housing.
19. Carefully install two piston rings (2) on sealing
bushing (1).
20. Arrange piston ring joints with 180 offset.
21. Install sealing bushing with chamfer (arrow)
facing compressor wheel rear side (upwards) in
rear wall (3).
Note: If necessary, compress piston ring with
screwdriver.
22. Position sealing bushing so that oil supply bore
of bearing housing is arranged at 90 offset
towards piston ring joint.
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23. Clean threads of screws (1) and in bearing
housing, ensuring that they are free of grease
and dry.
24. Coat screw threads with Loctite.
25. Place rear wall (2) according to the markings
onto bearing housing.
Note: Loctite curing process is completed after
approx. 24 hours only.
26. Install screws and washers and use torque wrench
to tighten to specified tightening torque. Values
( Page 980).
27. Remove sheet strip (3) between heat shield and
turbine wheel rear side.
28. Measuring turbine-side contour clearance:
28.1. Insert core assembly, without compressor
wheel and shaft nut, in turbine housing and
tighten with screws.
28.2. Position dial-gauge anvil on turbine wheel
hub.
29. Following this measurement, remove turbine
housing.
30. Measuring compressor-side contour clearance:
30.1. Push compressor wheel onto shaft. Insert
core assembly, without shaft nut, in
compressor housing and tighten with nuts.
30.2. Position dial-gauge anvil on compressor
wheel hub and set dial gauge to 0.
30.3. Lift compressor wheel as far as it will go and
31. Following this measurement, remove compressor
housing.
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Note: Do not subject shaft to bending stress.
32. Tighten new shaft nut (2) with Tee torque
wrench (1) to specified pretightening torque and
angle of further rotation. Values ( Page 980).
Note: The turbine-side piston rings are properly
seated if heat shield and bearing housing
can easily be rotated after the compressor
wheel has been installed.
33. Secure shaft nut and threaded journal of rotor with
screw locking varnish (arrow).
34. Measuring axial clearance:
34.1. Place dial-gauge anvil under preload on
turbine wheel hub.
note down measured value. Values
( Page 1405).
35. Measuring radial clearance:
Note: Radial clearance measurement is
required on turbine side only.
35.1. Place dial gauge stylus in the center of the
seating taper (arrow 1) of the turbine wheel.
35.2. Use dynamometer to pull down turbine
wheel hub at 50 N measurement force
(arrow 2).
35.4. Use dynamometer to pull up turbine wheel
hub at 50 N measurement force (arrow 2).
35.5. Note the reading at the dial gauge. Values
( Page 1405).
35.6. Rotate rotor through 90.
35.7. Repeat measurement.
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in groove in rear wall.
37. Place compressor housing (1) onto rear wall,
38. Fit clamping segments (2) and screw on new
nuts (1).
39. Use torque wrench to tighten nuts (1) to specified
tightening torque. Values ( Page 980).
40. Place turbine housing (3) onto bearing housing,
41. Coat thread of screws (1) with assembly paste.
42. Fit clamping segments (2) and insert screws (1).
specified tightening torque. Values ( Page 980).
44. Check rotor shaft for ease of movement.
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9.8.8 Exhaust turbocharger Installation
Special tools
Material
Assembly paste (Ultra Therm) 50547 1
Spare parts
Sealing ring
Sleeve
WARNING
Heavy object.
Risk of crushing!
Exhaust turbocharger Installation
1. Coat studs at threaded end with assembly paste.
2. Install studs and use torque wrench to tighten to specified tightening torque ( Page 980).
3. Fit new sealing rings in exhaust manifold.
4. Position exhaust turbocharger with crane and hook-ended chain sling.
5. Coat thread and nut contact faces with assembly paste.
6. Screw on nuts with sleeves and use torque wrench to tighten crosswise to specified tightening torque
( Page 980).
7. Check-tighten with same tightening torque.
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9.9 Charge-Air Cooling
9.9.1 Intercooler Overview
Intercooler
1 Elbow, left side
2 Vent line
3 End housing, top
4 Intercooler core
5 End housing, bottom
6 Elbow, right side
A Air inlet (from turbocharger)
B Air outlet (to cylinder)
C Coolant inlet
D Coolant outlet
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Intercooler and attachments
1 Intercooler
2 Plug screw
3 Connection housing, bottom
4 Dowel pin
5 Rubber profile
6 Hex bolt
7 Washer
8 Mounting bracket
9 Mounting bracket
10 Screw
11 Washer
12 Screw
13 Screw
14 Mounting bracket
15 Mounting bracket
16 Hex bolt
17 Washer
18 Hex bolt
19 Washer
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9.9.2 Intercooler Removal
Preconditions
WARNING
Heavy object.
Risk of crushing!
Intercooler Removal
1. Remove intercooler and elbow as per overview
2. Attach intercooler to crane with rope and carefully
raise from engine.
3. After removing intercooler, seal all connections on
engine with suitable plugs and covers.
4. Protect intercooler from damage. Cover cooler
meshes.
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9.9.3 Intercooler Cleaning
Work on the intercooler must always be carried out by qualified personnel.
The following sections contain instructions for the cleaning company.
Air-side cleaning
In the event of grease and oil contamination on the intercoolers air side, it is to be cleaned in a closed
cleaning unit. The cleaner must circulate in the opposite direction of the cooling air.
It is essential to avoid damaging the cooler, especially the cooling fins.
Water-side cleaning
It is recommended that the water side is cleaned in a closed cleaning unit with forced flushing and filter.
The water side can also be cleaned in an immersion or ultrasonic bath.
Intercooler Flushing
After cleaning, flush the intercooler with water until the pH values of the clean water and the flushing
water are the same (permissible difference pH value: 1 pH).
Intercooler Drying and preservation
If the cooler is not to be put into operation immediately after cleaning, the cooler is to be dried in a
drying oven for approx. 3 hours at a temperature of 110 to 120 C.
After drying, preserve the cooler with a preservative.
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9.9.4 Intercooler Check
Material
Emery cloth
Spare parts
Intercooler
Elbow
Holder
Plug-in pipe with bell
Plug-in pipe
Drain valve
WARNING
Compressed air.
Risk of injury!
WARNING
Component is hot.
Risk of burning!
WARNING
Hot testing liquid.
Intercooler Check
Item Findings Task
damage.
Damaged Recondition
Replace
unevenness.
Damaged
Uneven
Recondition:
smooth with oilstone or emery
cloth.
Replace
Intercooler Leak check
1. Seal coolant chamber connections on intercooler with suitable sleeves and covers with gaskets and clamps.
2. Connect compressed air line at plug.
4. Immerse intercooler in test bath.
5. Open compressed air supply and set pressure reducer to 0.5 bar.
6. Pressure-test intercoolers with air in water bath for leaks. Verify that no bubbles rise to the surface.
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7. Replace intercooler if leaks are found.
8. After checking, blow through cooling air ducts with compressed air in vertical direction.
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9.9.5 Intercooler Installation
Material
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
Intercooler Installation
2. Coat O-ring with petroleum jelly and place on
elbow flange.
3. Use crane to place intercooler on engine.
4. Screw screws (5) into mounting brackets (1).
5. Install elbow (3) to intercooler and secure with
screws (2) and nuts (4).
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9.10 Air Intake/Air Supply
9.10.1 Air intake / air supply Overview
1 Intercooler
3 Connecting elbow
5 Charge air line
6 Air intake
9 Air intake
11 Charge air line
12 Connecting elbow
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9.10.2 Intake housing Overview
Air Intake
1 Connecting piece
2 Rubber sleeve
3 Clamp
4 Clamp
5 Plug
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Air Intake
1 Elbow 2 Clamp
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9.10.3 Intake housing Removal
Preconditions
Intake housing Removal
1. Release clamps and remove air intake as shown in overview drawing ( Page 1422).
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9.10.4 Intake housing Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove intake housing ( Page 1424).
Intake housing Cleaning
2. Remove cleaner.
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9.10.5 Intake housing Check
Spare parts
Elbow
Rubber sleeve
Clamp
Plug
Connector
Clean intake housing ( Page 1425).
Intake housing Check
Check connector, elbow and rubber
sleeve for wear, cracks and damage.
Wear
Cracks
Damage
visible
Recondition
Replace
Check clamps, plug for ease of
movement.
Sluggish Recondition
Replace
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9.10.6 Intake housing Installation
Intake housing Installation
1. Remove all seals and plugs.
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9.10.7 Intake air system to cylinders, left Overview
3 O-ring
4 Gasket
5 Hex screw
6 Washer
7 Plug
8 Sealing ring
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9.10.8 Air supply system to cylinders, left-hand side Removal
Preconditions
Removing charge-air pipe
1. Remove charge-air pipe as shown in overview drawing, starting with the free end ( Page 1428).
3. After removal, seal all openings with plugs or covers.
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9.10.9 Air supply system to cylinders, left Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning charge-air manifold
1. Clean left charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
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9.10.10 Air supply to cylinders, left side Check
Material
Spare parts
Charge air manifold
Sealing ring
Screws
Plug screw
WARNING
Compressed air.
Risk of injury!
Checking air supply to cylinders, LHS
Item Findings Task
Leaks
at blanking plugs
Uneven
Damaged
oilstone.
Replace
movement.
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9.10.11 Air supply system to cylinders, left-hand side Installation
Material
Engine oil
Spare parts
O-ring
Gasket
CAUTION
CAUTION
Installing air supply system to cylinders, left-hand
side
manifold union (2).
faces (arrows).
with driving end.
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9.10.12 Air supply system to cylinders, right Overview
3 O-ring
4 Gasket
5 Hex screw
6 Washer
7 Plug
8 Sealing ring
9 Threaded bush
10 Sealing ring
11 Plug
12 Sealing ring
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9.10.13 Air supply system to cylinders, right-hand side Removal
Preconditions
Removing charge air manifold
1. Remove charge-air manifold as per overview drawing starting from the free end . ( Page 1433)
3. After removal, seal all openings with suitable plugs or covers.
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9.10.14 Air supply system to cylinders, right Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning the charge-air manifold
1. Clean right charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
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9.10.15 Air supply to cylinders, RHS Check
Material
Spare parts
Charge air manifold
Sealing ring
Screws
Plug screw
WARNING
Compressed air.
Risk of injury!
Checking air supply to cylinders, RHS
Item Findings Task
Leaks
at blanking plugs
Uneven
Damaged
oilstone.
Replace
movement.
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9.10.16 Air supply system to cylinders, right-hand side Installation
Material
Engine oil
Spare parts
O-ring
Gasket
CAUTION
CAUTION
Installing charge air manifold
manifold union (2).
faces (arrows).
with driving end.
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9.10.17 Air pipework from turbocharger to intercooler Overview
Air pipework 12V
2 O-ring
3 Spacer sleeve
4 Spacer sleeve
5 Screw
6 Screw
7 Connecting piece
8 O-ring
9 Clamp
10 Plug-in pipe
11 O-ring
12 O-ring
13 Elbow
14 O-ring
15 Screw
16 Washer
17 Nut
18 Connecting piece
19 O-ring
20 Clamp
21 Rubber sleeve
22 Clamp
23 Elbow
24 O-ring
25 Screw
26 Washer
27 Nut
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1 Connecting piece
2 O-ring
3 Clamp
4 Charge-air pipe
5 Rubber sleeve
6 Clamp
7 Retainer
8 Washer
9 Screw
10 Pipe half-clamp
11 Pipe half-clamp
12 Screw
13 Washer
14 Nut
15 Connecting piece
16 O-ring
17 Clamp
18 Charge-air pipe
19 Rubber sleeve
20 Clamp
21 Retainer
22 Washer
23 Screw
24 Pipe half-clamp
25 Pipe half-clamp
26 Screw
27 Washer
28 Nut
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Air pipework 16V
2 O-ring
3 Spacer sleeve
4 Spacer sleeve
5 Screw
6 Screw
7 Connecting piece
8 O-ring
9 Screw
10 Washer
11 Charge-air pipe
12 Rubber sleeve
13 Clamp
14 Plug-in pipe
15 O-ring
16 Elbow
17 O-ring
18 Screw
19 Washer
20 Nut
21 Retainer
22 Washer
23 Washer
24 Screw
25 Pipe half-clamp
26 Pipe half-clamp
27 Screw
28 Washer
29 Nut
30 Connecting piece
31 O-ring
32 Screw
33 Washer
34 Charge-air pipe
35 Rubber sleeve
36 Clamp
37 Connecting piece
38 O-ring
39 Screw
40 Washer
41 Elbow
42 O-ring
43 Screw
44 Washer
45 Nut
46 Retainer
47 Washer
48 Washer
49 Screw
50 Pipe half-clamp
51 Pipe half-clamp
52 Screw
53 Washer
54 Nut
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Intercooler elbow
1 Elbow
2 Plug screw
3 Plug screw
4 Elbow
5 Plug screw
6 O-ring
7 Screw
8 Nut
9 O-ring
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9.10.18 Air pipework from exhaust turbocharger to intercooler Removal
Preconditions
Air pipework from exhaust turbochargers to intercooler Removal
1. Remove air pipework as per overview drawing ( Page 1438).
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9.10.19 Air supply from turbocharger to intercooler Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning air pipework
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9.10.20 Air ducts from turbocharger to intercooler Check
Material
Spare parts
Charge air line
Connecting housing
Connecting elbow
Connector
Plug-in pipe
Rubber sleeve
Elbow
Spacer sleeve
Screw
Nut
Clamp
Bracket
Clean air ducts from turbocharger to intercooler ( Page 1443).
Air ducts from turbocharger to intercooler Check
Using the fluorescent penetrant dye method, check the
connecting housing, elbow, bracket and connection
elbow for cracks.
Check elbow and connection elbow with air under
water, max. air pressure 0.5 bar, for leaks.
Leaking:
at blanking plugs
at elbow
Replace blanking
plug.
Replace elbow.
Check sealing and bolt-on faces for evenness and
damage.
Uneven
Damaged
Recondition:
Smooth with
oilstone.
Replace
Check all threads for ease of movement. Sluggish Recut thread.
Replace thread
inserts.
Check connector, plug-in pipe, charge air line, screws,
clamps and plugs for damage and wear.
Damaged Replace
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9.10.21 Air pipework from turbocharger to intercooler Installation
Material
Spare parts
O-rings
CAUTION
Air pipework from turbocharger to intercooler Installation
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9.11 Exhaust System
9.11.1 Exhaust system Overview
Exhaust system
2 Exhaust system
5 Exhaust pipework connection
6 Exhaust system
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9.11.2 Exhaust pipework after cylinder head Overview
Exhaust pipework 16V (also applicable to 8V / 12V)
1 Exhaust pipe
2 Exhaust pipe
3 Exhaust pipe
4 Exhaust pipe
5 Bellows
6 V-band clamp
7 Insulation
8 Gasket
9 Screw
10 Spacer
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9.11.3 Exhaust pipework after cylinder head Removal
Preconditions
WARNING
Risk of injury!
Exhaust pipework Removal
1. Remove gasket (1).
2. Screw nut onto stud (2) and secure with second
nut.
3. Remove stud (2).
4. Remove screws (1) from band clamps (2).
5. Take off band clamps carefully.
6. Take off insulation.
7. Remove other insulation parts in the same way.
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8. Remove V-band clamps (2) from bellows (1).
9. Remove bellows (1).
10. Remove other bellows in the same way.
11. Remove all screws (1) from exhaust pipes and
take off spacers (2).
12. Remove all exhaust pipes.
13. Seal exhaust ports on cylinder head with suitable
plugs.
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9.11.4 Exhaust pipework after cylinder head Clean
Material
WARNING
Compressed air.
Risk of injury!
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning exhaust pipework after exhaust turbocharger
2. Place components with deposits in a container with decarbonizer. Time for cleaning depends on the layer
thickness of the deposits.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
5. Remove cleaner.
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9.11.5 Exhaust pipework after cylinder head Check
Material
Spare parts
Exhaust pipe
Bellows
Hex screw
Gasket
Exhaust pipework after cylinder head Check
Using the surface crack-test
method and red penetrant
dye, check exhaust pipe and
bellows for cracks.
Check hex screws for
damage.
Damaged Replace
Check parts for stress marks,
wear and distortion.
Stress marks
Wear
Distortion
visible
Replace
Check sealing and mating
faces for evenness and
damage.
Uneven
Damaged
Recondition: Smooth with oilstone
Replace
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9.11.6 Exhaust pipework after cylinder head Installation
Special tools
Material
Engine oil 40453 1
Spare parts
Gasket
WARNING
Heavy object.
Risk of crushing!
Exhaust pipework Installation
2. Fit gaskets (1) on all cylinder head exhaust flanges.
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3. Position exhaust pipe starting from engine free
end.
4. Coat screws (1) with engine oil.
5. Insert screws (1) with spacers (2).
6. Tighten screws crosswise.
7. Fit gaskets (arrow) on both flange faces of the
exhaust pipe bellows.
8. Fit two V-band clamps (2) over exhaust pipe
bellows.
9. Position exhaust pipe bellows between exhaust
pipe flanges.
10. Use alignment device (1) to align collar of exhaust
pipe flange and exhaust pipe bellows flush.
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11. Push V-band clamp (2) centrally over flange collar
of exhaust pipe flange and exhaust pipe bellows
and secure with screws.
12. Remove alignment device (1).
13. Push second V-band clamp centrally over flange
collar of exhaust pipe flange and exhaust pipe
bellows and secure with screws.
14. Install further exhaust pipe bellows in the same
way.
15. Fit insulation (2) over exhaust pipe bellows and
secure with band clamps (1).
16. Position band clamps (1) so that screws are
accessible in horizontal position.
17. Tighten screws.
18. Install further insulation parts in the same way.
19. Fit gaskets (1).
20. Insert studs (2) with the small thread ahead into
the flange for the exhaust turbocharger.
21. Tighten studs with locknuts.
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9.11.7 Exhaust pipework after exhaust turbocharger Overview
Exhaust pipework
1 Exhaust elbow 2 Screw 3 Washer
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1 Bellows
2 Sealing ring
3 Clamp
4 Sealing ring
5 Clamp
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9.11.8 Exhaust pipework after exhaust turbocharger Removal
Preconditions
Exhaust pipework after exhaust turbocharger Removal
1. Remove exhaust pipework as per overview drawing ( Page 1455).
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9.11.9 Exhaust pipework after turbocharger Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove exhaust pipework after exhaust turbocharger ( Page 1457).
Exhaust pipework after turbocharger Cleaning
5. Remove cleaner.
6. Blow out exhaust lines thoroughly.
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9.11.10 Exhaust pipework after exhaust turbocharger Check
Material
Spare parts
Exhaust elbow
Washer
Bellows
Clamp
Checking exhaust pipework after exhaust turbocharger
Item Findings Task
Check exhaust elbow with red dye
Check parts for stress marks, wear
and deformation.
Stress marks
Wear
Deformation
visible
Replace
flatness and damage.
Uneven
Damaged
Corrective work: Smoothen
with oilstone
Replace
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9.11.11 Exhaust pipework after exhaust turbocharger Installation
Material
Spare parts
Sealing ring
Exhaust pipework after exhaust turbocharger Installation
1. Prior to assembly, coat screw threads with assembly paste.
2. Install exhaust elbow and bellows as per overview drawing ( Page 1455).
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9.11.12 Exhaust pipework after engine Overview
1 Bellows
2 Sealing ring
3 Clamp
4 Insulation
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Companion flange
1 Flange
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9.11.13 Exhaust pipework after engine Removal
Exhaust pipework after engine Removal
1. Remove exhaust pipework according to overview drawing ( Page 1461).
2. After removal, seal all openings.
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9.11.14 Exhaust pipework after engine Cleaning
Material
Cleaner
Decarbonizer
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove exhaust pipework after engine ( Page 1463).
Exhaust pipework after engine Cleaning
5. Remove cleaner.
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9.11.15 Exhaust pipework after engine Check
Spare parts
Flange
Clamp
Insulation
Clean exhaust pipework after engine ( Page 1464).
IExhaust pipework after engine Check
Check exhaust pipe bellows and flange for wear
and distortion.
Traces of wear
Wear
Deformation
visible
Replace
Check insulation for damage Damaged Replace
Check clamps for ease of movement. Sluggish Recondition
Replace
Check sealing and mating faces for evenness and
damage.
Uneven
Damaged
Recondition: smooth
with oilstone
Replace
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9.11.16 Exhaust pipework after engine Installation
Material
Spare parts
Sealing ring
Check exhaust pipework after engine ( Page 1465).
Exhaust pipework after engine Installation
2. Install exhaust pipe bellows as shown in overview drawing ( Page 1461).
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9.12 Starting Equipment
9.12.1 Electric starter Overview
1 Starter (for 12V/16V on left
engine side)
2 Starter, right engine side
3 Hex screw / Allen screw
4 Gear ring
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1 Terminal 45
2 Terminal 30
3 Terminal 50
4 Housing for engagement lever
5 Engagement relay
6 Commutator cover
7 Terminal 31
8 Starter housing
9 Driver housing
10 Terminal 30
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9.12.2 Starter Removal
Preconditions
DANGER
Electrical voltage.
WARNING
Heavy object.
Risk of crushing!
Disconnecting and removing starter
1. Before disconnecting, mark all cables with writable
adhesive tape for identification.
Connection terminal 30 = positive cable
Connection terminal 50 = control cable
Connection terminal 31 = ground cable
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Depending on the version, remove hex screws or
Allen screws (1) from starter.
5. Remove starter.
6. Protect starter from damage.
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9.12.3 Starter Disassembly
Starter Disassembly
Entrust starter overhaul to an authorized and specialized company only.
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9.12.4 Starter Cleaning
WARNING
Compressed air.
Risk of injury!
Starter Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against humidity.
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9.12.5 Starter Check
Spare parts
Starter
WARNING
Compressed air.
Risk of injury!
Starter Check
Item Findings Task
Check tooth flanks of drive gear for
wear, indentations and chipping.
Wear
Indentations
Chipping
visible
Recondition
Replace
Check nuts and studs for condition
and check threads for ease of
movement.
Sluggish Replace
Check mating face on end housing
for wear.
Wear traces are found. Recondition: smooth with oilstone
or emery cloth.
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9.12.6 Starter Installation
Material
Long-life grease (Longtherm 2 Plus) 40336 1
DANGER
Electrical voltage.
WARNING
Heavy object.
Risk of crushing!
Installing starter
1. Coat starter pinion with long-life grease.
2. Attach starter to crane.
3. Insert starter into opening on end housing.
4. Align bores for securing screws on starter with
those on flange.
5. Secure starter to flange with screws (1).
Connecting starter cables
1. Connect cables as per marking on starter ( Page 1469).
(1) = terminal 45 = internal control cable (already connected)
(2) = terminal 30 = positive cable
(3) = terminal 50 = control cable
(4) = terminal 31 = ground cable
2. Check operation of starter.
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9.12.7 Flame starting system Overview
1 Flange
2 Insulating washer
3 Nut
4 Fuel nipple
5 Sealing element
6 Protective shroud
7 Screw
8 Screw
9 Fuel line
10 T-piece
11 Fuel line
12 Fuel line
13 T-piece
14 Fuel line
15 Fuel line
16 Fuel line
17 Bracket
18 Pipe half-clamp
19 Grommet
20 Screw
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1 Bracket
2 Bracket
3 Screw
4 Screw
5 Screw
6 Washer
7 Pressure regulator
8 Screw
9 Spacer bush
10 Pipe half-clamp
11 Screw
12 Union
13 Sealing ring
14 Bracket
15 Screw
16 Screw
17 T-piece
18 Fuel line
19 Adapter
20 Sealing ring
21 Fuel line
22 Adapter
23 Sealing ring
24 Adapter
25 Sealing ring
26 Fuel line
27 Adapter
28 Sealing ring
29 Pipe half-clamp
30 Grommet
31 Screw
32 Fuel line
33 Bracket
34 Screw
35 Washer
36 Pipe half-clamp
37 Pipe half-clamp
38 Grommet
39 Screw
40 Fuel line
41 Bracket
42 Screw
43 Pipe half-clamp
44 Grommet
45 Screw
46 Fuel line
47 Bracket
48 Pipe half-clamp
49 Grommet
50 Screw
51 Fuel line
52 Non-return valve
53 Fuel line
54 Non-return valve
55 Bracket
56 Pipe half-clamp
57 Grommet
58 Screw
59 Fuel line
60 Fuel line
61 Blanking cone
62 Nut
63 Fuel line
64 Non-return valve
65 Fuel line
66 Grommet
67 Grommet
68 Pipe half-clamp
69 Pipe half-clamp
70 Pipe half-clamp
71 Pipe half-clamp
72 Washer
73 Spacer pipe
74 Screw
75 Bracket
76 Screw
77 Grommet
78 Pipe half-clamp
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9.12.8 Flame starting system Removal
WARNING
Do not smoke.
Removing flame torches
1. Remove screws (arrowed) from protective cover.
2. Hold sealing element (2) securely and carefully
remove protective cover.
3. Removing fuel lines (1).
5. Disconnect control cable at connections (arrowed).
6. Remove sealing element (2).
7. Release flange (4).
8. Remove flame torch (3).
9. Remove insulating washer (5).
Removing fuel lines and externally mounted components
1. Before removing the lines, take photos or mark lines and externally mounted components.
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9.12.9 Flame starting system Cleaning
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove flame starting system ( Page 1476).
Flame starting system Cleaning
3. Blow out all components thoroughly with compressed air.
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9.12.10 Flame starting system Check
Spare parts
Flange
Insulating washer
Nut
Fuel nipple
Sealing element
Protective shroud
Fuel line
T-piece
Bracket
Bracket
Pressure regulator
Spacer bush
Union
WARNING
Risk of injury!
Clean flame starting system ( Page 1477).
Flame starting system Check
Visually check all fuel lines and attachments for
damage.
Damaged Recondition
Replace
Check fuel lines with air bottom water for leaks.
Maintain a coolant temperature of min. = 30 C or
Leaking Replace
Check all threads for damage and ease of
movement.
Damaged
Thread sluggish.
Recondition:
Recut thread.
Replace
Check sealing and screw-on surfaces for damage. Damaged Recondition:
Smooth with
oilstone.
Replace
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9.12.11 Flame starting system Installation
Spare parts
Sealing ring
Grommet
WARNING
Do not smoke.
CAUTION
Check flame starting system ( Page 1478).
Install flame starting system
2. Blow fuel lines clear with compressed air.
3. Install fuel lines without tension as shown in the overview drawing ( Page 1474) or as per photos/marks
made during removal.
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9.13 Lube Oil System, Lube Oil Circuit
9.13.1 Lube-oil pump with drive Overview
1 Oil pump
2 Screw
3 Washer
4 Screw
5 Pressure reducing valve
6 Banjo screw
7 Sealing ring
8 Oil line
9 Retainer
10 Pipe half-clamp
11 Grommet
12 Screw
13 Spacer sleeve
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9.13.2 Lube-oil pump with drive Removal
Special tools
WARNING
Heavy object.
Risk of crushing!
Removing oil pump with safety valve
Note: The illustration does not show engine in
1. Unscrew all screws (1) on the oil pump (2).
2. Attach support bracket to oil pump and with rope,
slightly tensioned, to crane.
3. Remove oil pump from equipment carrier and
place aside.
Removing oil line and pressure reducing valve
1. Remove oil line from equipment carrier as per overview drawing ( Page 1480).
2. Remove pressure reducing valve from equipment carrier.
4. Seal connections with suitable plug.
5. Protect oil line from damage.
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9.13.3 Lube-oil pump with drive Disassembly
Lube-oil pump Disassembly
1. Do not disassemble lube oil pump.
2. Contact Service.
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9.13.4 Lube oil pump with drive Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning oil line
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9.13.5 Lube-oil pump with drive Check
Material
Spare parts
Oil pump
Pressure reduction valve
Oil line
Banjo screw
Screw
Pipe half-clamp
WARNING
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Lube-oil pump with drive Check
Item Findings Task
Visually inspect outside of lube-oil
pump for damage and defects.
Damaged Have lube-oil pump operation
checked and repaired at
manufacturer.
Visually inspect oil line for damage. Damaged Corrective work
Replace
Check sealing faces for irregularities. Uneven Corrective work and check for
evenness with ink-check plate.
Replace
Damaged
Sluggish
Replace
Check drive gear with dye penetrant
for cracks.
Check tooth flanks of drive gear
for stress marks, indentations and
chipping.
Stress marks
Indentations
Chipping
visible
Corrective work
Replace lube-oil pump
Check breather valve for opening
pressure of 15 bar. Test medium:
Engine oil SAE 30 medium
temperature: from 90 C to 100 C.
Opening pressure not reached or
exceeded.
Replace
Disassembly of the pressure
reduction valve is not planned;
check for damage by visual
inspection only.
Damaged Replace
Check pressure reduction valve
opening pressure. Operation: The
valve limits the oil flow so that a
constant pressure of 5.5 +1 bar is
maintained at the last crankshaft
bearing. Medium temperature: from
90 C to 100 C, design pressure at
n/min 1.5 bar at n/max 7 bar of oil
pump.
Opening pressure not reached, or
exceeded.
Replace
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9.13.6 Lube oil pump with drive Installation
Special tools
Material
Engine oil
Spare parts
Sealing ring
Grommet
O-ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Heavy object.
Risk of crushing!
WARNING
Compressed air.
Risk of injury!
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Installing lube oil pump on equipment carrier
1. Degrease sealing face on equipment carrier
and lube-oil pump.
2. Apply surface sealant to sealing surface on
equipment carrier.
3. Attach oil pump with carrying bracket to crane.
4. Insert oil pump into equipment carrier, making
sure gears engage correctly.
5. Screw in screws (1) and (2) for oil pump and use
torque wrench to tighten diagonally to specified
tightening torque .
Installing pressure reducing valve
1. Coat O-ring with grease and insert in groove of
pressure reducing valve (arrow).
2. Insert pressure reducing valve (1) in equipment
carrier and tighten to specified torque using a
torque wrench .
Pressure reducing
valve
Tightening torque Engine oil 60 Nm +20 Nm
Installing oil line
2. Blow out oil line with compressed air.
3. Install oil line loosely using attaching parts as per overview drawing ( Page 1480).
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9.13.7 Oil filter Overview
Oil filter housing
1 Oil filter housing
2 O-ring
3 O-ring
4 Hex screw
5 Washer
6 Bracket
7 O-ring
8 O-ring
9 Hex screw
10 Hex screw
11 Oil Filter
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1 Sealing ring
2 Washer
3 Hex nut
4 Connector
5 Pipe
6 Adapter
7 Differential pressure monitor
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9.13.8 Oil filter with oil filter housing Removal
Special tools
Removing oil filter
1. Remove oil filter with filter wrench.
2. Drain oil from oil filter into a suitable container.
Removing oil filter housing
1. Remove oil filter housing according to overview
2. Seal connections (arrows) with plugs.
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9.13.9 Oil filter housing Disassembly
Remove oil filter housing ( Page 1490).
Oil filter housing Disassembly
1. Remove threaded fittings (3) from oil filter housing
(2).
2. Unscrew all plugs.
3. Remove O-rings (5).
4. Remove plug (3) and remove valve.
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9.13.10 Oil filter housing Clean
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning oil filter housing
2. Blow out/off all parts with compressed air.
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9.13.11 Oil filter housing Check
Special tools
Test bath
Spare parts
Oil filter housing
Bracket
Connector
Pipe
Adapter
Nut
Washer
WARNING
Hot testing liquid.
Clean oil filter housing ( Page 1492).
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Oil filter housing Check
sliding surfaces for wear, scoring
and indentations.
Wear
Scores
Indentations
visible.
Recondition: smooth with oilstone or
emery cloth.
Replace
bores.
Damaged Recondition: recut thread.
Replace
Pressure-test oil filter housing
with air in water bath for leaks.
Install filter inserts before carrying
out leak check. Test temperature:
min. 30 C, max. 40 C, if oil filter
housing has to be held in hands.
Test pressure: 0.5 bar.
Leaking Replace plugs.
Replace valve.
Replace oil filter housing.
Check differential pressure
monitor, bracket and line for
mechanical damage.
Damaged Replace
Check spring of pressure limiting
valve for wear.
Wear Replace
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9.13.12 Oil filter housing Assembly
Material
Spare parts
O-rings
Plugs
CAUTION
Check oil filter housing ( Page 1493).
Oil filter housing Assembly
1. Screw threaded fittings (3) into oil filter housing (2).
2. Coat O-rings for plugs (4) with petroleum jelly.
3. Screw in plugs.
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4. Coat O-rings for grooves with petroleum jelly.
5. Insert valve with spring in bore (3).
6. Insert plug (3).
7. Insert O-rings in grooves.
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9.13.13 Oil filter with oil filter housing Installation
Material
Engine oil
Spare parts
O-rings
CAUTION
Assemble oil filter housing ( Page 1495)
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Installing oil filter housing
2. Install oil filter housing as shown in overview
4. Insert O-ring in groove (1) of oil filter housing (2).
Installing oil filter
1. Coat sealing ring of oil filter with oil.
2. Install oil filter and tighten by hand.
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9.13.14 Centrifugal oil filter Overview
Centrifugal oil filter with attachments
2 Hex screw
3 Washer
4 Sealing ring
5 Sealing ring
6 Adapter
7 Sealing ring
8 Oil line
9 Hex nut
10 Screw
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Centrifugal oil filter with flange
2 Flange
3 O-ring
4 Screw
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Centrifugal oil filter assembly
1 Housing
2 Valve
3 Sealing ring
4 Valve piston
5 Plug
6 Compression spring
7 O-ring
8 Cover
9 Cover
10 Cover screw
11 Screw
12 Pin
13 O-ring
14 Drain screw
15 Clamp
16 Rotor unit
17 Nozzle
18 Substructure with bearing
19 Standpipe
20 Snap ring
21 O-ring
22 Pin
23 Knurled nut
24 Insertion sleeve
25 Reinforcing plate
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9.13.15 Centrifugal oil filter Removal
Preconditions
Centrifugal oil filter Removal
1. Remove centrifugal oil filter as shown in overview drawing ( Page 1499).
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9.13.16 Centrifugal oil filter Disassembly
Disassembling centrifugal oil filter
1. Release nut with toggle (2) and remove V-band
clamp (1).
2. Release screw from cover (1).
3. Remove cover (1) from housing (2).
4. Drain residual oil from centrifugal oil filter into a
suitable container.
5. Carefully remove rotor unit (1) from
shaft/housing (3). Avoid damaging bearing
or shaft.
7. Remove valve piston, plug and pressure spring as
shown in the overview drawing ( Page 1499).
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Note: Take care not to interchange rotors
belonging to different centrifugal filters
because rotor hood and substructure are
aligned to one another during manufacture.
8. Release knurled nut (1) and remove rotor hood (3)
with cover plate (2) from rotor substructure (4).
9. Remove paper element from rotor hood (3).
10. Remove pipe (1) from rotor (2).
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9.13.17 Centrifugal oil filter Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning the rotor unit
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9.13.18 Centrifugal oil filter Check
Material
Spare parts
Housing
Rotor
Nozzle
Pipe
Screw
Compression spring
Valve plunger
Plug
Centrifugal oil filter Check
Item Findings Task
Check all sealing, mating and sliding
surfaces for wear, scoring and
indentations.
Wear
Scores
Indentations
visible.
Replace
housing and substructure for cracks.
Cracks indicated Replace rotor unit.
bores.
Damaged Recondition: recut threads.
Replace
Check journals on rotor and bearing
running surfaces on shaft for wear.
Wear visible Recondition: smooth with
Replace
Check valve piston and spring
( Page 1499) for wear traces.
Wear visible Recondition
Replace
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9.13.19 Centrifugal oil filter - Bearing clearance check
Special tools
Retainer 0015890321/00 1
Spare parts
Rotor
Clean centrifugal oil filter ( Page 1505).
Checking bearing clearance of rotor
1. Arrange dial gauge with dial gauge stylus opposite rotor.
2. Align dial gauge stylus to upper rotor edge, set dial gauge to zero.
5. Align dial gauge stylus to lower rotor edge, set dial gauge to zero.
8. Measure bearing diameter:
Diameter at upper bearing running surface of shaft: 14.98 mm
Diameter at lower bearing running surface of shaft: 21.63 mm
Inner diameter of upper bearing: 15.06 mm
Inner diameter of lower bearing: 21.69 mm
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9.13.20 Centrifugal oil filter Assembly
Special tools
Material
Engine oil
Spare parts
Paper element
O-ring
Sealing ring
WARNING
Heavy object.
Risk of crushing!
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Assembling rotor unit
1. Fit pipe (1) on rotor (2).
2. Insert gaiter (2) in cover (1).
3. Coat O-ring (arrowed) with grease and insert
in groove on cover.
4. Fit cover (1) with new paper element (2) on rotor.
5. Turn cover (1) so that chase (3) and pin (4) are
flush with one another.
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6. Install cover plate (2) and tighten knurled nut (1)
by hand.
7. Coat shaft with engine oil.
8. Carefully insert rotor unit in housing (2).
9. Check that rotor rotates freely.
10. Coat O-ring with grease and insert in groove (1)
on housing (2).
11. Place cover (1) on housing (2) and use torque
wrench to tighten cover screw to specified
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12. Install V-band clamp (1) and use torque wrench
to tighten nut (2) to specified tightening torque
( Page 980).
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9.13.21 Centrifugal oil filter Installation
Material
Spare parts
O-ring
CAUTION
CAUTION
Centrifugal oil filter Installation
2. Coat O-ring with grease and insert.
3. Install centrifugal oil filter as shown in overview drawing ( Page 1499).
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9.13.22 Oil heat exchanger Overview
1 Insert
2 O-ring
3 Housing
4 O-ring
5 Washer
6 Nut
7 Screw
8 Screw
9 Plug-in pipe
10 O-ring
11 Retainer
12 Nut
13 O-ring
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9.13.23 Oil heat exchanger Removal
Preconditions
Special tools
Eyebolt B80090843 2
WARNING
Hot oil.
WARNING
Heavy object.
Risk of crushing!
Removing oil heat exchanger
1. Remove screws (3) from oil heat exchanger
housing.
2. Remove nuts (1).
3. Screw eyebolts (2) into the left and right oil heat
exchanger housing.
4. Using crane and rope, remove oil heat exchanger
housing from coolant distribution housing.
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5. Remove sealing washers (1).
6. Carefully remove oil heat exchanger (arrowed)
vertically upwards from coolant distribution
housing fit.
7. Seal all openings and connections with suitable
plugs.
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9.13.24 Oil heat exchanger Cleaning
Material
Cleaning agent
CAUTION
CAUTION
Cleaning oil heat exchanger housing and plug-in pipe
1. Clean oil heat exchanger housing and plug-in pipe with cleaner.
Cleaning oil heat exchanger on water and oil side.
Note: If swarf has got into the engine oil system, e.g. as a result of piston scuffing or bearing damage, replace oil
heat exchanger.
Cleaning water side
1. Examine the degree of contamination.
2. In event of visible encrustation as a result of hardness structure, contamination and oil deposits, clean with
suitable cleaners, e.g. Porodox (from Henkel) or Porozink (from Parobe-Chemie, Basel). Always follow
manufacturers instructions.
3. After cleaning, flush the oil heat exchanger with water until pH values of clean water and flushing liquid are
approximately the same (difference 1 pH).
4. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve coolant side.
Cleaning oil side
1. Connect oil heat exchanger (oil side) to a closed flushing system with a filter system of 0.05 mm mesh size.
2. Clean oil heat exchanger with suitable cleaner, e.g. buffered alkaline agents such as 3 to 5% solution
of Henkel P3 FD.
3. Ensure flow direction of cleaner is against normal direction of oil flow during operation.
4. After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are
roughly equal (permissible difference 1pH).
5. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve oil side.
Drying and preserving oil heat exchanger
1. Dry oil heat exchanger in oven at 110 C to 120 C for approx. 3 hours.
2. Spray preservative (Branorol 32/10 from Brangs & Heinrich) into the oil heat exchanger. A dosage of max.
2 ml Branorol 32/10 per litter of cooling volume must be observed. The preservative vaporizes and forms a
protective film on all interior surfaces.
3. After preservation, seal all openings airtight with suitable plugs.
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9.13.25 Oil heat exchanger Check
Material
Red dye penetrant for surface crack-testing procedure
Spare parts
Oil heat exchanger housing
Heat exchanger core
Retainer
Plug-in pipe
WARNING
Compressed air.
Risk of injury!
WARNING
Hot testing liquid.
WARNING
Component is hot.
Risk of burning!
CAUTION
Oil heat exchanger check
damage.
Replace
unevenness.
Damaged
Uneven
Corrective work:
Smooth with oilstone or crocus
cloth.
Replace
Check thread for easy movement. Sluggish Recut
Replace
Check oil heat exchanger housing
for cracks with red dye penetrant.
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Heat exchanger core leak check
1. Seal oil chamber connections of heat exchanger
core (3) with suitable sleeves, blanking plugs,
plugs (2) and clamps.
2. Connect pressure line (1) at plug (2).
4. Immerse heat exchanger core (3) in test bath.
5. Open compressed air supply and set pressure
reducer (1) to 0.5 bar.
6. Pressuretest heat exchanger core (3) for leaks
with air in water bath; no bubbles should emerge.
7. Replace heat exchanger core (3) if leaky.
8. Remove compressed-air line (1), sleeves and
plug (2).
9. Blow out cooling fins of heat exchanger core (3)
with compressed air in vertical direction.
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9.13.26 Oil heat exchanger Installation
Special tools
Eyebolt B80090843 2
Material
Engine oil (MZK engine oil HD 10W) 40453 1
Spare parts
O-ring
O-ring
WARNING
Heavy object.
Risk of crushing!
CAUTION
Installing oil cooler
1. Remove all plugs from coolant distribution housing.
2. Clean oil chambers and oil galleries (arrowed).
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3. Coat O-rings on heat exchanger core with grease.
4. Place heat exchanger core in coolant distribution
housing with label IN towards the driving end.
5. Place disks (1) on the threads of the heat
exchanger cores.
on the elbow (2).
7. Loosen screws on elbow (2).
on the oil heat exchanger housing (2).
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9. Coat O-rings on plug-in pipe (2) with grease
before installation.
10. Mount plug-in pipe (2) with retainer (3) on oil heat
exchanger housing (1).
11. Screw eyebolts into the oil heat exchanger
housing (1).
12. Using crane and rope, position oil heat exchanger
housing (1) on coolant distribution housing.
13. Screw oil heat exchanger housing (1) into place
with the screws on the coolant distribution housing.
14. Remove eyebolts (2) from both oil heat exchanger
housings.
16. Screw on nuts (1) and tighten with torque wrench
to the specified tightening torque ( Page 980).
17. Tighten the screws (2) on the elbow (1) of the
coolant distribution housing.
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9.13.27 Oil system in crankcase Overview
Oil system
1 Delivery valve
2 O-ring
3 O-ring
4 Circlip
5 Washer
6 O-ring
7 O-ring
8 Retainer
9 Retainer
10 Pipe
11 Pipe
12 Oil spray nozzle
13 Screw
14 Circlip
15 Delivery valve
16 O-ring
17 O-ring
18 Washer
19 O-ring
20 O-ring
21 Retainer
22 Retainer
23 Pipe
24 Pipe
25 Oil spray nozzle
26 Screw
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1 Delivery valve
2 O-ring
3 Washer
4 O-ring
5 Pipe
6 Retainer
7 Retainer
8 Retainer
9 Oil spray nozzle
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9.13.28 Oil system in crankcase Removal
Preconditions
Special tools
WARNING
Risk of injury!
Removing bracket for oil spray nozzle
1. Install barring device at crankshaft ( Page 1145).
2. Turn crankshaft with barring device until oil spray
nozzle (1) to be removed is accessible.
3. Remove screws (arrows).
4. Remove oil spray nozzle (1) from retainer (2).
5. Mark oil spray nozzle (1) with a pen according to
cylinder side and cylinder number.
6. Protect oil spray nozzle (1) against damage.
Removing oil pipe connection
1. Remove screw (arrows).
2. Remove holder (2) from oil pipe fit (3).
3. Remove oil pipe (1) from retainer (2).
4. Remove all other oil spray nozzles in same
manner.
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Removing washer (sealing fit)
1. Remove washer (2) from crankcase (1).
2. Remove O-rings.
3. Protect washer (2) against damage.
Removing delivery valve
1. Remove pressure valve as per overview drawing
( Page 1522).
2. Unscrew plug screws.
3. Remove snap ring (1) from housing.
4. Remove delivery valve (3) from housing.
5. Remove O-rings (2) and (4)
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9.13.29 Oil pipework in crankcase Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning oil spray nozzles and oil pipes
2. Remove cleaner.
3. Blow oil pipes, retainers and oil spray nozzle dry with compressed air.
Cleaning washer (sealing fit)
2. Remove cleaner.
3. Then blow washer dry (sealing fit) with compressed air.
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9.13.30 Oil pipework in crankcase Check
Special tools
Material
Spare parts
Oil spray nozzle
Pipe
Retainer
Washer (sealing fit)
Delivery valve
DANGER
Component to be tested is under pressure.
Risk of explosion!
Observe test specification.
WARNING
Risk of injury!
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Oil pipework in crankcase Check
Item Findings Task
Check oil spray nozzles with dye
Check oil bore of oil spray nozzles
for obstruction and ensure it is
particularly clean.
Contamination visible. Corrective work: Clean
Replace
Check oil spray nozzle with testing
device for deformation.
Deformation of oil spray nozzle. Replace
Test oil pipes for leaks with air in
water bath as necessary. Maintain a
of 0.5 bar.
Leaking Replace
movement.
Replace
Check mating and sealing faces of
oil spray nozzle.
Damaged
Stress marks
visible
Replace
Check washer (sealing fit) for wear,
cracks and damage.
Stress marks
Cracks
Damage
visible
Replace
Check bore in crankcase for wear. Visible signs of wear. Smooth with emery cloth.
Do not disassemble delivery valve!
Visually inspect delivery valve for
damage.
Damaged Replace
Check delivery valve for read
opening pressure 0.25 bar.
Fallen short of or exceeded Replace delivery valve.
Check sealing face of delivery valve
for evenness.
Uneven Corrective work: Smooth with
oilstone.
Replace
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9.13.31 Oil system in crankcase Installation
Special tools
Material
Engine oil
Spare parts
O-rings
Snap ring
WARNING
Compressed air.
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Installing oil spray nozzle bracket and oil pipes
2. Install bracket (1) so that dimension "a" points
towards crankcase.
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3. Coat O-rings with grease and insert into grooves in
oil pipes (1) and (3).
4. Fit oil pipes (1) and (3) in retainer (2) and secure
with screws (arrow) on crankcase.
5. Install oil spray nozzle (1) on retainer and align
with alignment device (3).
specified tightening torque.
7. After installing, bar engine and ensure there is
clearance between oil spray nozzle and piston.
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Installing washer (sealing fit)
1. Coat O-rings with grease and insert into grooves
(arrows) of washer.
2. Align oil pipe so that inner O-ring is not damaged.
3. Press-fit washer (2) manually in crankcase (3).
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Installing delivery valve
1. Coat O-ring (arrow) with grease and insert in
groove (arrow).
2. Coat O-ring (arrow) with grease and insert into
groove on delivery valve.
3. Insert delivery valve (3) into bore of housing
4. Secure delivery valve with snap ring (1) and
install plug screw.
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9.13.32 Turbocharger oil supply Overview
ETC oil supply
1 Oil line
2 O-ring
3 Screw
4 O-ring
5 Threaded adapter
6 O-ring
7 Retainer
8 Washer
9 Screw
10 Washer
11 Pipe half-clamp
12 Pipe half-clamp
13 Grommet
14 Washer
15 Screw
16 Retainer
17 Washer
18 Screw
19 Washer
20 Pipe half-clamp
21 Pipe half-clamp
22 Grommet
23 Washer
24 Screw
25 Oil line
26 O-ring
27 Screw
28 O-ring
29 Threaded adapter
30 O-ring
31 Retainer
32 Washer
33 Screw
34 Washer
35 Pipe half-clamp
36 Pipe half-clamp
37 Grommet
38 Washer
39 Screw
40 Retainer
41 Washer
42 Screw
43 Washer
44 Pipe half-clamp
45 Pipe half-clamp
46 Grommet
47 Washer
48 Screw
49 Oil line
50 Oil line
51 Gasket
52 Screw
53 Gasket
54 Nut
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9.13.33 Turbocharger oil supply Removal
Preconditions
Turbocharger oil supply Removal
1. Remove oil line, unions and fixtures as per overview drawing ( Page 1533).
2. Remove all sealing elements.
4. Protect oil lines from damage.
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9.13.34 Turbocharger oil supply Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Turbocharger oil supply Cleaning
2. Remove cleaner.
3. Blow turbocharger oil supply pipework dry with compressed air.
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9.13.35 Turbocharger oil supply Check
Spare parts
Pipe
Flange
Adapter
Strap
WARNING
Compressed air.
Risk of injury!
WARNING
Risk of injury!
Turbocharger oil supply Check
Item Findings Task
Visually inspect oil return line for
damage.
Damaged Replace
Pressure-test oil return line with air
in water bath for leaks. Maintain a
of 0.5 bar.
Leaking Replace
Check connection parts and
securing elements on oil return lines
for damage.
Damaged Replace
Check sealing and bolt-on faces. Damaged Corrective work: Smooth with
Replace
movement.
Replace
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9.13.36 Turbocharger oil supply Installation
Material
Engine oil
Spare parts
O-rings
Grommet
Sealing ring
Pipe half-clamp
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
Turbocharger oil supply Installation
2. Coat O-rings with grease and insert.
3. Insert sealing rings.
4. Install turbocharger oil supply ( Page 1533).
5. After starting the engine, visually inspect oil lines for leaks.
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9.14 Coolant System
9.14.1 Coolant system Overview
Coolant circuit with internal thermostat
1 Intercooler
coolant circuit)
coolant circuit)
6 Fan cooler
air coolant system)
9 Thermostat for cooler fan
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
19 Crankcase
cooling circuit
preheating unit
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Coolant circuit with external thermostat
1 Intercooler
coolant circuit)
coolant circuit)
6 Fan cooler
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
coolant circuit)
17 Crankcase
preheating unit
cooling circuit
air coolant system)
24 Dummy thermostat, open, blocked
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9.14.2 Engine coolant pump Overview
2 O-ring
3 Screw
4 Screw
5 Screw
6 Nut
7 Washer
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1 Water pump shaft
2 Impeller
3 Bearing housing
4 Seal carrier
5 Volute
6 Spacer sleeve
7 Gear
10 Snap ring
11 Shaft seal
12 Rotary seal
13 O-ring
14 O-ring
15 O-ring
16 Screw
17 Washer
18 Screw
19 Washer
20 Sealing ring
21 Plug screw
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Special tools
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
1. Attach engine coolant pump with lifting gear and support bracket to crane using a slightly tensioned rope.
2. Remove screws for engine coolant pump as per overview drawing DM_410_WM_202050_041A.
3. Use crowbar to separate engine coolant pump from front cover and remove.
4. Remove O-ring.
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9.14.4 Engine coolant pump Disassembly
Special tools
Press fit tool F30379316 1
WARNING
Heavy object.
Risk of crushing!
WARNING
WARNING
Risk of injury!
Engine coolant pump Disassembly
2. Remove all screws (2) securing the volute (3) to
the bearing housing (1).
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device (1).
pump shaft.
throughout.
8. Take engine coolant pump out of retaining device.
9. Place bearing housing (3) with pump shaft in vise
with aluminum jaws.
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housing (1).
12. Remove all screws (1) for seal carrier using a
box wrench (2).
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17. Use hydraulic press (1) and mandrel (2) to
press cylindrical roller bearing (3) out of bearing
housing (4).
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18. Use screwdriver to press counterring (2) out
of impeller (1).
19. Remove shaft seal, intermediate washer and
rotary shaft seal (arrow) from seal carrier (3) with
mandrel (2) and hydraulic press (1).
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9.14.5 Engine coolant pump Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Engine coolant pump Cleaning
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9.14.6 Engine coolant pump Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Material
Penetrant remover (Standard-Check) 40002 1
Spare parts
Engine coolant pump
Water pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
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Engine coolant pump Check
Item Findings Task
cavitation.
for cracks.
Check water pump shaft with
fluorescent magnetic powder for
cracks.
Check coolant pump shaft for wear
and damage.
Wear
Damage
visible
Replace
Wear
Pitting
Cavitation
visible
Replace
of wear and damage.
Wear
Indentations
Damage
visible
Replace gear.
diameters on engine coolant
pump, impeller, seal carrier and
bearing housing and gear with
inside and outside micrometer.
Values and measuring points
DM_410_WM_202050_276A
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9.14.7 Engine coolant pump Tolerances
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Seal carrier 90.000
K7
0.025 +0.010 1
Angular-contact
ball bearing
outer diam.
90.000 0.015 0
0.025 0.025
Bearing housing
bore
90.000
K7
0.025 +0.010 2
Angular-contact
ball bearing
outer diam.
90.000 0.015 0
0.025 0.025
Angular contact
ball bearing bore
40.000 0.012 0 3
k5
+0.002 +0.013
0.002 0.025
Spacer sleeve
bore
40.000
N7
0.033 0.008 4
k5
+0.002 +0.013
0.010 0.046
Bearing housing
bore
80.000
K7
0.021 +0.009 5
Cylindrical roller
bearing
80.000 0.013 0
0.022 0.021
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Cylindrical roller
bearing bore
40.000 0.012 0 6
k5
+0.002 +0.013
0.002 0.025
Gear bore 39.000
H7
0 +0.025 7
s6
+0.043 +0.059
0.018 0.059
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
H8
0 +0.046 1
Shaft seal outer
diam.
72.000 +0.130 +0.230
0.084 0.230
Shaft outer diam. 48.000 0.100 0 2
H7
0 +0.030 3
Rotary seal outer
diam.
78.200 0.030 0
0.040 0.100
H5
0 +0.009 4
t5
+0.041 +0.050
0.032 0.050
Rotary seal
Counterring
5
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9.14.8 Engine coolant pump Assembly
Special tools
Press fit tool for angular-contact ball bearings F30378152 1
Press fit tool for ball bearings F30378153 1
Press fit tool for shaft seal F30378550 1
Press fit tool for rotary seal F30378151 1
Support for bearing housing F6780563 1
Support for shaft with bearing F6781573 1
Material
Ethanol 40250 1
Engine oil
Spare parts
Snap ring
Shaft seal
Rotary seal
O-ring
WARNING
Component is hot.
Risk of burning!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
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CAUTION
Engine coolant pump Assembly
Note: Apply pressure to bearing outer race.
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4. Force angular-contact ball bearing (3) onto pump
shaft (4) with hydraulic press (1) and mandrel (2).
5. Force spacer sleeve (3) onto pump shaft (4) with
6. Press inner race (2) of cylindrical roller bearing
onto pump shaft (3) with hydraulic press and
mandrel (1).
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Note: Apply pressure to bearing outer race (3).
position.
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10. Place intermediate washer in seal carrier (4).
11. Coat rotary shaft seal (3) with a soap solution
(water : soap mixture = 2:1).
rotary shaft seal (3) into seal carrier (4).
13. Clean running surface with ethanol after assembly.
14. Coat O-ring with petroleum jelly and place into
groove.
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Note: Insert counterring (2) only after heating.
counterring (2).
22. Place counterring (2) in heated impeller (1).
23. Clean counterring surface with ethanol.
24. Place engine coolant pump onto hydraulic
press (1).
25. Place two feeler gauges (clearance
S1 = 0.7 mm to 1.1 mm), on seal carrier (3)
arranged at 180 towards one another.
26. Push heated impeller (2) with hydraulic press (1)
until it stops at feeler gauges.
27. Measure clearance S1 between impeller (2) and
seal carrier (3) with feeler gauge.
removal.
31. Turn pump shaft to check for easy movement.
32. Measure clearance S2 (0.6 mm to 1.5 mm)
between impeller and volute (3) with feeler gauge.
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Special tools
Material
Engine oil
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
engine coolant pump.
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4. Attach engine coolant pump with lifting gear and
support bracket to crane using a slightly tensioned
rope.
Note: Observe tooth meshing.
5. Install engine coolant pump (1) in bore on
equipment carrier, ensuring correct installation
position.
6. Install screws (2) with washers and tighten
uniformly.
7. Remove lifting gear with support bracket.
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9.14.10 Coolant pipework of engine coolant pump, intake side Overview
Elbow with attachments
1 Elbow
2 Plug screw
3 Sealing ring
4 O-ring
5 Screw
6 Washer
7 Holder
8 Screw
9 Washer
10 Drain valve
11 Connector
12 Banjo screw
13 Sealing ring
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Plug-in pipe with flange
1 Plug-in pipe
2 O-ring
3 Flange
4 Screw
5 O-ring
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Coolant pipework
1 Plug-in pipe
2 O-ring
3 Flange
4 Screw
5 O-ring
6 Plug-in pipe
7 O-ring
8 Flange
9 Screw
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9.14.11 Coolant pipework for engine coolant pump, intake side Removal
Preconditions
Coolant pipework for engine coolant pump, intake side Removal
2. Remove all monitoring units installed in coolant lines.
3. Remove coolant pipework for engine coolant pump on intake side as shown in overview drawing
( Page 1562).
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9.14.12 Coolant pipework, engine coolant pump, suction side Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning coolant lines
3. Blow dry coolant lines with compressed air and preserve in oil bath.
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9.14.13 Coolant pipework, engine coolant pump, suction side Check
Spare parts
Elbow
Flange
Plug-in pipe
Retainer
Connecting piece
Drain valve
WARNING
Risk of injury!
Coolant pipework, engine coolant pump, suction side, check
Visually inspect retainers, plug
connections and annular grooves on
elbows and connecting lines for wear,
Wear
Pitting
Cavitation
visible
Replace
wear and damage.
Replace
Pressure-test coolant lines with air
in water bath for leaks as necessary.
Maintain a coolant temperature of min.
= 30 C or max. = 40 C at a test
Leaking Replace
Check operation of drain valve. Damaged Replace
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9.14.14 Coolant pipework, engine coolant pump, suction side Installation
Material
Engine oil
Spare parts
Sealing rings
O-rings
WARNING
Compressed air.
Risk of injury!
Install coolant lines
2. Blow out coolant lines with compressed air.
3. Coat all O-rings with grease.
4. Install coolant lines without tension using new sealing and O-rings as shown in the overview drawing
( Page 1562).
5. Install all monitoring units in coolant lines.
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9.14.15 Coolant pipework after cylinder Overview
Coolant pipework after cylinder Overview
Also applies analogously to 12 V.
1 Connecting piece
2 Screw
3 O-ring
4 Connecting piece
5 Screw
6 Screw
7 O-ring
8 Plug screw
13 O-ring
14 O-ring
15 O-ring
16 Screw
17 Screw
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9.14.16 Coolant pipework after cylinder Removal
Preconditions
Coolant pipework after cylinder Removal
1. Remove manifolds as per overview drawing ( Page 1569).
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9.14.17 Coolant pipework after cylinder Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning coolant pipework after cylinder
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9.14.18 Coolant pipework after cylinder Check
Spare parts
Manifold
Connecting piece
WARNING
Compressed air.
Risk of injury!
WARNING
Hot testing liquid.
Checking coolant pipework after cylinder
Visually inspect plug connections and
annular grooves on connecting piece and
manifold for wear, pitting and cavitation.
Replace
Check manifold with air and corrosion
inhibitor in water bath for leaks. Maintain
a coolant temperature of min. = 30 C or
Leaking Replace
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9.14.19 Coolant pipework after cylinder Installation
Material
Engine oil
Spare parts
O-ring
WARNING
Compressed air.
Risk of injury!
Coolant pipework after cylinder Installation
2. Blow out manifolds with compressed air.
4. Install manifolds free of tension as shown in overview drawing ( Page 1569).
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9.14.20 Engine coolant drain lines Overview
Coolant lines
1 Pipe
2 Sealing cone
3 Nut
4 Pipe
5 Pipe
6 Sealing cone
7 Nut
8 Pipe
9 T adapter
10 Sealing cone
11 Nut
12 Retainer
13 Pipe half-clamp
14 Grommet
15 Hex screw
16 Washer
17 Hex nut
18 Hex screw
19 Spacer bushing
20 Retainer
21 Hex screw
22 Spacer bushing
23 Pipe half-clamp
24 Pipe half-clamp
25 Grommet
26 Hex screw
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9.14.21 Engine coolant drain lines Removal
Removing drain lines
1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and externally
mounted components.
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0
0
4
1
2
1
0
0
3
9.14.22 Engine coolant drain lines Cleaning
Special tools
Cleaning brush
Material
Cleaning agent
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
Remove engine coolant drain lines ( Page 1575).
Cleaning engine coolant drain lines
1. Clean coolant drain lines with cleaning agent and cleaning brush.
3. Blow dry coolant drain lines with compressed air and preserve in oil bath.
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9.14.23 Engine coolant drain lines Check
Spare parts
Pipe
Sealing cone
T adapter
Retainer
Spacer bushing
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Checking engine coolant drain lines
Check T piece, retainers and lines for
damage.
Damaged Replace
Pressure-test lines with air and
corrosion inhibitor in water bath for
leaks as necessary. Maintain a coolant
Leaking Replace
Check thread for damage and easy
movement
Damaged or sluggish Corrective work: recut threads
Replace
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9.14.24 Engine coolant drain lines Installation
Material
Engine oil
Spare parts
Grommet
WARNING
Compressed air.
Risk of injury!
Installing engine coolant drain lines
2. Blow out coolant drain lines with compressed air.
3. Install engine coolant drain lines as shown in the overview drawing ( Page 1574) without tension and
secure with pipe half-clamps.
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9.14.25 Engine coolant and charge air coolant ventilation Overview
Coolant vent lines (also applies to 16V)
25 Union
30 Sealing ring
45 Vent line
55 Bracket
60 Washer
65 Screw
70 Pipe half-clamp
75 Grommet
80 Screw
90 Union
95 Sealing ring
100 Vent line
110 T-piece
120 Bracket
125 Pipe half-clamp
130 Grommet
135 Screw
145 T-piece
155 Vent line
165 Vent line
170 Union
175 Sealing ring
185 Vent line
195 T-piece
205 Vent line
210 Union
215 Sealing ring
225 Vent line
235 Adapter
240 Sealing ring
260 Vent line
265 Adapter
270 O-ring
305 Bracket
310 Pipe half-clamp
315 Pipe half-clamp
325 Grommet
330 Screw
340 Spacer bush
460 Adapter
465 O-ring
470 Vent line
475 Adapter
480 Sealing ring
490 Threaded union
495 Vent line
505 Bracket
510 Pipe half-clamp
515 Grommet
520 Screw
525 Vent line
535 Bracket
540 Pipe half-clamp
545 Grommet
550 Screw
553 Vent line
555 Vent line
565 Bracket
570 Pipe half-clamp
575 Grommet
580 Screw
585 Spacer bush
590 Pipe half-clamp
595 Grommet
600 Screw
605 Pipe
610 Adapter
615 Sealing ring
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250 T-piece
280 Vent line
290 Union
295 Sealing ring
350 Vent line
355 Threaded union
365 Bracket
366 Screw
367 Washer
370 Pipe half-clamp
375 Pipe half-clamp
380 Grommet
390 Distributor
395 Bracket
400 Screw
402 Plug
403 Plug
410 Threaded union
415 Pipe
420 Union
425 Sealing ring
435 Pipe half-clamp
440 Pipe half-clamp
445 Grommet
450 Screw
621 Union
622 Sealing ring
630 Pipe
640 T-piece
650 Pipe
655 Elbow
700 Threaded union
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9.14.26 Engine coolant and charge-air cooling vent Removal
Preconditions
Engine coolant and charge-air cooling vent Removal
1. Prior to removal of the lines take photos or mark attachments and lines.
2. Remove engine coolant and charge-air cooling vent ( Page 1579).
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9.14.27 Ventilation, engine coolant and charge air coolant Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning ventilation, engine coolant and charge air coolant
2. Thoroughly blow out coolant and charge air cooling ventilation with compressed air and preserve in oil bath.
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9.14.28 Ventilation, engine coolant and charge air coolant Check
Spare parts
Pipe
Elbow
Vent line
Distributor piece
T adapter
Retainer
Bracket
Spacer sleeve
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Checking ventilation, engine coolant and charge air coolant
Check lines, elbow, distributor, T piece, retainer,
bracket and spacer sleeve for damage.
Damaged Replace
Check coolant lines for leaks in water bath, using
compressed air and corrosion inhibitor. Maintain a
coolant temperature of min. = 30 C or max. = 40 C
at a test pressure of 0.5 bar.
Leaking Replace
Check thread for damage and easy movement. Damaged or sluggish Corrective work: recut
threads
Replace
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9.14.29 Engine coolant and charge-air cooling vent Installation
Material
Engine oil
Spare parts
Grommet
Pipe clamp half
WARNING
Compressed air.
Risk of injury!
CAUTION
CAUTION
Engine coolant and charge-air cooling vent Installation
2. Install engine coolant and charge-air cooling vent as shown in overview drawing ( Page 1579).
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9.14.30 Coolant pipework from/to exhaust turbochargers Overview
1 Adapter
2 Sealing ring
3 Coolant line
4 Adapter
5 Sealing ring
6 Coolant line
7 Holder
8 Pipe half-clamp
9 Pipe half-clamp
10 Grommet
11 Washer
12 Screw
13 Adapter
14 Sealing ring
15 Coolant line
16 Adapter
17 Sealing ring
18 Coolant line
19 Adapter
20 Sealing ring
21 Coolant line
22 Adapter
23 Sealing ring
24 Coolant line
25 Pipe half-clamp
26 Pipe half-clamp
27 Grommet
28 Washer
29 Screw
30 Adapter
31 Sealing ring
32 Coolant line
33 Pipe half-clamp
34 Pipe half-clamp
35 Grommet
36 Washer
37 Screw
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9.14.31 Coolant pipework from/to exhaust turbochargers Removal
Preconditions
Removing coolant lines
2. Remove coolant pipework from/to exhaust turbochargers as shown in overview drawing ( Page 1585).
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9.14.32 Coolant pipework from/to exhaust turbochargers Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
CAUTION
Coolant pipework from/to exhaust turbochargers Cleaning
1. Clean parts with cleaning agent and cleaning brush.
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9.14.33 Coolant pipework from/to turbochargers Check
Spare parts
Coolant line
Bracket
Pipe half-clamp
Grommet
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Clean coolant pipework from/to exhaust turbochargers ( Page 1587).
Coolant pipework from/to turbochargers Check
Visually check lines, pipe clamp halves,
grommets and brackets for damage.
Damaged Replace
Check coolant lines for leaks in water bath,
using compressed air and corrosion inhibitor.
Maintain a coolant temperature of min. = 30 C
or max. = 40 C at a test pressure of 0.5 bar.
Leaking Replace
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9.14.34 Coolant pipework from/to exhaust turbochargers Installation
Material
Engine oil
CAUTION
CAUTION
Coolant pipework from/to exhaust turbochargers - Installation
1. Before installation, remove all covers.
2. Install coolant pipework from/to exhaust turbochargers as shown in the overview drawing ( Page 1585).
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9.14.35 Charge-air coolant pump Overview
1 Charge-air coolant pump
2 O-ring
3 Screw
4 Screw
5 Nut
6 Washer
7 Drain valve
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1 Water pump shaft
2 Impeller
3 Bearing housing
4 Seal carrier
5 Volute
6 Spacer sleeve
7 Gear
10 Snap ring
11 Shaft seal
12 Rotary seal
13 O-ring
14 O-ring
15 Screw
16 Washer
17 O-ring
18 Screw
19 Washer
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9.14.36 Charge-air coolant pump Removal
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
Charge-air coolant pump Removal
1. Remove screws for charge-air coolant pump according to overview drawing DM_410_WM_203050_041A.
2. Use crowbar to separate charge-air coolant pump from equipment carrier and remove.
3. Mask installation hole for charge-air coolant pump.
4. Remove O-ring from charge-air coolant pump.
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9.14.37 Charge-air coolant pump Disassembly
Special tools
Retaining device 5505890531/00 1
Press fit tool F30379316 1
WARNING
Heavy object.
Risk of crushing!
WARNING
WARNING
Risk of injury!
Charge-air coolant pump - Disassembly
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4. Insert charge-air coolant pump (2) into retaining
device (1).
pump shaft.
throughout.
7. Remove impeller (3) from charge-air coolant pump.
8. Remove charge-air coolant pump from retaining
device.
9. Place bearing housing (3) with pump shaft in vice
with aluminum jaws.
remove gear from water pump shaft
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housing (1).
12. Remove all bolts (1) using box wrench (2).
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16. Use hydraulic press (1) to force water pump shaft
cylindrical roller bearing out of bearing housing (4).
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18. Use screwdriver to press counterring (2) out
of impeller (1).
19. Use hydraulic press (1) and ejection mandrel (2) to
press shaft seal and rotary seal (arrow) out of
seal carrier (3).
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9.14.38 Charge-air coolant pump Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Charge-air coolant pump Cleaning
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9.14.39 Charge-air coolant pump Tolerances
size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Seal carrier 90.000
K7
0.025 +0.010 1
Angular-contact
ball bearing
outer
90.000 0.015 0
0.025 0.025
Bearing housing
bore
90.000
K7
0.025 +0.010 2
Angular-contact
ball bearing
outer
90.000 0.015 0
0.025 0.025
Angular-contact
ball bearing bore
40.000 0.012 0 3
Shaft outer 40.000
k5
+0.002 +0.013
0.002 0.025
Spacer sleeve
bore
40.000
N7
0.033 0.008 4
Shaft outer 40.000
k5
+0.002 +0.013
0.010 0.046
Bearing housing
bore
80.000
K7
0.021 +0.009 5
Cylindrical roller
bearing
80.000 0.013 0
0.022 0.021
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
Cylindrical roller
bearing bore
40.000 0.012 0 6
Shaft outer 40.000
k5
+0.002 +0.013
0.002 0.025
Gear bore 39.000
H7
0 +0.025 7
Shaft outer 39.000
s6
+0.043 +0.059
0.018 0.059
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size
Tol. size
Basic
size
lower
upper
min.
max.
min.
max.
H8
0 +0.046 1
Shaft seal
outer
72.000 +0.130 +0.230
0.084 0.230
Shaft outer 48.000 0.100 0 2
H7
0 +0.030 3
Rotary seal
outer
78.200 0.030 0
0.040 0.100
H5
0 +0.009 4
Shaft outer 30.000
t5
+0.041 +0.050
0.032 0.050
Rotary seal
Counterring
5
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9.14.40 Charge-air coolant pump Check
Special tools
Bore gauge, 18-100 mm Y20091481 1
Material
Dye penetrant remover (Standard-Check) 40002
Aqueous developer (Standard-Check) 40004
Dye penetrant (Standard-Check) 40488
Spare parts
Charge-air coolant pump
Pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
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Charge-air coolant pump Check
Item Findings Task
cavitation.
for cracks.
Check pump shaft with fluorescent
magnetic powder for cracks.
Check pump shaft for wear and
damage.
Wear traces
Damage
visible
Replace
Wear
Pitting
Cavitation
visible
Replace
of wear and damage.
Wear traces
Indentations
Damage
visible
Replace gear.
diameters on pump shaft, impeller,
seal carrier and bearing housing
and gear with inside and outside
micrometer. Values and measuring
points DM_410_WM_203050_276A
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9.14.41 Charge-air coolant pump Assembly
Special tools
Press fit tool for angular-contact ball bearings F30378152 1
Press fit tool for ball bearings F30378153 1
Press fit tool for shaft seal F30378550 1
Press fit tool for rotary seal F30378151 1
Support for bearing housing F6780563 1
Seat for shaft with bearing F6781573 1
Material
Ethanol 40250 1
Corrosion inhibitor oil
Spare parts
Snap ring
Shaft seal
Rotary seal
O-ring
WARNING
Component is hot.
Risk of burning!
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
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Charge-air coolant pump Assembly
Note: Apply pressure to bearing outer race.
4. Force angular-contact ball bearing (3) onto
water pump shaft (4) with hydraulic press (1)
and mandrel (2).
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5. Force spacer sleeve (3) onto pump shaft (4) with
6. Press inner race (2) of cylindrical roller bearing
onto pump shaft (3) with hydraulic press and
mandrel (1).
Note: Apply pressure to bearing outer race (3).
pump shaft into bearing housing (4).
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position.
10. Use denatured ethanol to clean sliding and
counterring surfaces of the rotary seal, and the
seal carrier.
11. Coat outer surface of rotary seal (3) with surface
sealant.
rotary shaft seal (3) into seal carrier (4).
13. Clean running surface with ethanol after assembly.
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groove.
Note: Insert counterring (2) only after heating.
21. Coat O-ring (2) with corrosion inhibitor oil and
place into counterring.
22. Place counterring (2) in heated impeller (1).
23. Clean counterring surface with denatured ethanol.
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24. Place charge-air coolant pump on hydraulic
press (1).
25. Use hydraulic press (1) to push heated impeller (2)
onto coolant pump shaft to stop position.
removal.
28. Turn pump shaft to check freedom of rotation.
29. Use feeler gauge to check clearance S2 (0.6 mm to
1.52 mm) between impeller and volute (3).
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9.14.42 Charge-air coolant pump Installation
Material
Engine oil
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
WARNING
Risk of injury!
CAUTION
CAUTION
Preparing charge-air coolant pump for installation
3. Insert O-ring (1) in groove on the bearing housing
of charge-air coolant pump.
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4. Insert charge-air coolant pump (1) into the
bore in the equipment carrier, ensuring correct
5. Screw in screws (2) with washers.
6. Tighten screws (2) evenly.
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9.14.43 Coolant pipework from/to intercooler Overview
1 Pipe
2 Gasket
3 Screw
4 Holder
5 Screw
6 Nut
7 Coolant line
8 Plug screw
9 Coolant line
10 Rubber sleeve
11 Clamp
12 Holder
13 Spacer washer
14 Screw
15 Coolant line
16 Coolant line
17 Coolant line
18 Rubber sleeve
19 Clamp
20 Holder
21 Spacer washer
22 Screw
23 Gasket
24 Screw
25 Washer
26 Plug screw
27 Sealing ring
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1 Adapter union
2 Sealing ring
3 Drain line
4 Drain valve
5 Holder
6 Screw
7 Washer
8 Pipe half-clamp
9 Grommet
10 Screw
11 Drain line
12 Drain valve
13 Holder
14 Screw
15 Washer
16 Spacer bushing
17 Pipe half-clamp
18 Grommet
19 Screw
20 Drain valve
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9.14.44 Coolant pipework from/to intercooler Removal
Preconditions
Removing coolant pipework
1. Before removing the lines, it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as per overview drawing ( Page 1612).
3. Remove sealant.
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9.14.45 Coolant pipework from/to intercooler Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
CAUTION
Cleaning coolant pipework from/to intercooler
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9.14.46 Coolant pipework from/to intercooler Check
Spare parts
Coolant line
Pipe
Rubber sleeve
Gasket
Retainer
Drain valve
Screw
Hex nut
Spacer washer
Spacer bushing
Plug screw
WARNING
Risk of injury!
WARNING
Compressed air.
Risk of injury!
Checking coolant pipework from/to intercooler
Check sealing surfaces for flatness. Uneven Corrective work: smooth
with oilstone or crocus
cloth.
Replace
Check all components for damage. Damaged Replace
Check thread for easy movement and
damage.
Damaged or sluggish Corrective work: recut
threads
Replace
Pressure-test coolant lines with air and
corrosion inhibitor in water bath for leaks as
necessary. Maintain a coolant temperature
of min. = 30 C or max. = 40 C at a test
Leaking Replace
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9.14.47 Coolant pipework from/to intercooler Installation
Material
Engine oil
White petroleum jelly 40314 1
WARNING
Compressed air.
Risk of injury!
Installing coolant pipework from/to intercooler
2. Blow out coolant pipework from/to intercooler with compressed air.
3. Install coolant pipework from/to intercooler as shown in the overview drawing ( Page 1612) and secure with
pipe half-clamps, ensuring the installation is free of tension.
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9.14.48 Coolant pipework with thermostat Overview
Coolant pipework with thermostat
1 Coolant distribution housing
2 Cover
3 O-ring
4 Screw
5 Cover
6 Screw
7 Blind flange
8 O-ring
9 Screw
10 Elbow
11 Gasket
12 Screw
13 O-ring
14 O-ring
15 O-ring
16 Screw
17 Screw
18 O-ring
19 Screw
20 Screw
21 Thermostat housing (high-
23 Sealing ring
24 O-ring
25 Screw
26 Screw
27 O-ring
28 Restrictor
29 Thermostat housing (low-
31 Sealing ring
32 Screw
33 Screw
34 Washer
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9.14.49 Coolant pipework with thermostat Removal
Preconditions
DANGER
Suspended load.
Danger to life!
Removing thermostat housing (high temperature
circuit)
1. Remove screws from flanges (1) and (2).
2. Press the flanges off the sealing surfaces.
3. Remove pipes (3) and (4) as shown in the
4. Remove flange (1).
5. Remove screws (2) from thermostat housing (5).
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6. Replace two screws from thermostat housing with
guide pins (arrowed).
7. Remove thermostat housing from coolant
distribution housing.
8. Remove thermostat inserts, sealing rings, and
O-rings.
Removing coolant distribution housing
1. Screw eyebolts into coolant distribution housing
and suspend the housing using crane and rope.
2. Remove screws and washers for coolant
distribution housing as shown in the overview
3. Using crane and rope, remove coolant distribution
housing from gearcase.
4. Remove O-rings.
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Removing thermostat housing (low temperature circuit)
1. Remove screws from thermostat housing.
2. Remove thermostat housing as shown in the overview drawing ( Page 1618).
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9.14.50 Coolant pipework with thermostat Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning coolant pipework with thermostat
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9.14.51 Coolant pipework with thermostat Check
Material
Spare parts
Coolant distribution housing
Thermostat housing
Thermostat insert
Cover
Blind flange
Elbow
Restrictor
WARNING
Compressed air.
Risk of injury!
WARNING
Component is hot.
Risk of burning!
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Checking coolant pipework with thermostat
Check all components for condition
and damage.
Damaged Replace
coolant distribution housing and
thermostat housing for cracks.
Check all mating and sealing
surfaces for wear and damage.
Wear
Damage
visible
Replace
Check support bores of thermostat
elements for damage.
crocus cloth.
Replace
Check threads in coolant distribution
housing for easy movement.
Gaskets, sealing rings and O-rings

Replace
Check coolant and oil chambers
of coolant distribution housing for
leaks with air and corrosion inhibitor
under water. Maintain a coolant
Leaking Replace
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Checking thermostat element (high- and
low-temperature circuits)
Technical data, thermostat elements
Hightemperature circuit Start of
open-
ing (B) =
75 C 2 C
Full open-
ing (A) =
88 C 2 C
Lowtemperature circuit Start of
open-
ing (B)
= 38
C 2 C
Full open-
ing (A)
= 51
C 2 C
Note: The thermostat element must not be in
contact with the container.
1. Suspend the thermostat element by means of a
wire in a container filled with water.
2. Heat water with suitable heat source.
Note: Start-of-opening temperature is stamped
on thermostat insert.
3. Check thermostat insert for start of opening
with heat supply uniform and water constantly
circulated. At approx. 10C below opening
temperature (B), the heating speed must not
exceed 1C per minute.
4. Replace thermostat insert if results of check
are negative.
5. Continue to heat coolant to full-opening
temperature (A).
Result: Thermostat insert must be completely
open after 6 to 8 minutes.
6. Measure stroke travel of thermostat insert. Stroke
must be min. 9.5 mm.
7. If stroke travel is less than 9.5 mm, replace
thermostat insert.
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9.14.52 Coolant pipework with thermostat Installation
Special tools
Eyebolt 000580010000 2
Driving mandrel F30379297 1
Material
Engine oil
Spare parts
O-rings
DANGER
Suspended load.
Danger to life!
CAUTION
Installing coolant distribution housing
1. Coat Orings with petroleum jelly and insert into
grooves (1) in equipment carrier.
2. Insert plug screw (2).
3. Coat mating face of coolant distribution housing on
equipment carrier with Loctite 518 (arrowed).
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Note: When fitting coolant distribution housing
in position, make sure O-rings are not
damaged.
4. Carefully place coolant distribution housing on
equipment carrier with crane and rope and align.
5. Secure coolant distribution housing as shown in
the overview drawing ( Page 1618).
Installing thermostat elements
1. Fit sealing ring (2) with flat side to installation
mandrel (1).
2. Drive sealing rings with installation mandrel flush
into thermostat housing.
3. Coat sealing surfaces (arrowed) of thermostat
elements with petroleum jelly.
4. Insert thermostat elements.
6. Insert O-rings in groove.
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Installing thermostat housing (high-temperature
circuit)
1. Insert restrictor (arrowed) into support bore.
2. Install thermostat housing on coolant distribution
housing by means of guide pins.
3. Insert securing screws (2) of thermostat
housing (5).
4. Install flange (1).
5. Install pipelines (3,4) as shown in the overview
6. Install flange (1,2).
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9.15 Power Supply, Engine Side
9.15.1 Battery-charging generator - Overview
1 Battery-charging generator
2 Coupling
3 Carrier
4 Shaft
5 Gear
6 Snap ring
8 Spacer ring
9 Spacer ring
10 Grooved ball bearing
11 Shaft seal
12 O-ring
13 Screw
14 Washer
15 Screw
16 Washer
17 Generator bracket
18 Screw
19 Guard plate
20 Holder
21 Screw
23 Washer
24 Holder
25 Screw
26 Washer
27 Screw
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9.15.2 Battery-charging generator Removal
Special tools
WARNING
Heavy object.
Risk of crushing!
Removing battery-charging generator
1. Mark and disconnect battery-charging generator
cables.
3. Remove holder (6) and bracket (3).
4. Remove screws (1) and plate (5).
5. Withdraw battery-charging generator (4) from
carrier seating and coupling.
Removing coupling from battery-charging generator
1. Install battery-charging generator in support (1).
2. Remove nut (3).
3. Remove battery-charging generator from support.
4. Remove coupling (2) from support.
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Removing coupling from shaft
2. Remove coupling (3).
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9.15.3 Battery-charging generator Disassembly
Disassembling battery-charging generator
Have battery-charging generator overhauled by an authorized workshop only.
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9.15.4 Battery-charging generator Cleaning
Material
WARNING
Compressed air.
Risk of injury!
WARNING
CAUTION
Cleaning battery-charging generator
1. Clean generator with compressed air only; do not use any liquids in cleaning process.
2. Clean all metal parts using cleaner (Snow-White 11-0) and rinse with cleaner (Hakupur 312).
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9.15.5 Battery-charging generator - Check
Spare parts
Coupling
Carrier
Shaft
Gear
Spacer ring
Grooved ball bearing
Gear
Bracket
Guard plate
Holder
Clean battery-charging generator ( Page 1633).
Checking battery-charging generator
Item Findings Task
Inspect battery-charging generator
externally for damage.
Damaged Replace
Check all contact and mating
Damaged Recondition: Re-surface with
oil stone or crocus cloth.
Replace
Check thread for ease of movement. No ease of movement Recondition: Re-cut thread(s).
Replace
Check battery-charging generator
drive for abnormal running noises.
Abnormal running noises Contact Service.
Check gear for indentations, signs
of wear and damage.
Indentations
Signs of wear
Damage
visible
Recondition: Re-surface with
crocus cloth or oil stone.
Replace gear.
Check coupling for cracks and
swellings.
Swellings
Cracks
visible.
Replace
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9.15.6 Battery-charging generator Installation
Special tools
Material
Engine oil
Spare parts
Shaft seal
WARNING
Heavy object.
Risk of crushing!
Check battery-charging generator ( Page 1634).
Installing antifriction bearings and gear on carrier
1. Install antifriction bearings (5-9) on carrier (1).
2. Coat sealing lip of radial-lip shaft seal (10) with
engine oil.
3. Press radial-lip shaft seal into carrier until the
stop is reached.
Note: Heat gear to 180C +20C.
4. Install shaft (3) and gear (4) using the press-in
tool and ensuring that an thrust distance of 0.1 to
0.88 mm is achieved.
5. Coat O-ring (2) with petroleum jelly and position
in groove.
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Installing coupling on shaft
1. Check screws (1) for correct tightening torque
( Page 980).
2. Install coupling (3) ensuring correct positioning.
3. Install positioning fixture to lock the engine.
4. Install screw (2) and tighten to specified tightening
torque ( Page 980).
Installing battery-charging generator drive
1. Install coupling (2) in installation tool (1).
2. Fit generator in installation tool.
3. Position Woodruff key on shaft.
4. Tighten nut to specified tightening torque
( Page 980).
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Installing battery-charging generator
Note: Ensure correct positioning of pins (1).
1. Install battery-charging generator (4) with
coupling (3) to coupling (2) ensuring there is no gap
between the resilient element and the intermediate
plate. Torsion of max. 1.0 mm is permissible.
2. Install holder (6) with bracket (3), ensuring that
parts are not placed under tension.
4. Align battery-charging generator (4).
5. Tighten screws (2) to specified tightening torque
using a torque wrench ( Page 980).
6. Install plate (5) using screws (1).
7. Connect cables as per marking.
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9.16 Mounting/Support
9.16.1 Engine mounting / support Overview
Engine mounting / support
1 Engine mounting bracket 2 Engine mount
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9.16.2 Engine mounting Overview
1 Washer
2 Hex screw
3 Nut
4 Washer
5 Resilient mount
6 Hex screw
7 Washer
9 Dowel pin
10 O-ring
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Engine mounting brackets
2 Screw
4 Screw
5 Screw
6 Nut
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9.16.3 Engine mount Removal
Special tools
DANGER
Danger to life!
DANGER
Suspended load.
Danger to life!
Engine mount Removal
Note: Replace rubber mounts individually, one
after the other.
1. Install engine supports with engine installed.
2. Insert engine support jackscrews until they make
contact with the foundation and secure the engine
against damping element static deflection.
3. Unscrew all foundation screw fittings on damping
element to be removed.
4. Use locking screws (5) to pull damping elements
together evenly until engine carrier can be
removed.
5. If the gap between base mount and foundation is
not large enough, proceed as follows:
5.1. Remove protective cap (1) and loosen
nut (3).
5.2. Insert height adjusting screw (4) as far as
possible in bearing cap. Make sure not to
twist central buffer. Hold firmly in position at
hexagon (2) if necessary.
6. Remove screws (1,2,4) with washers (3) from
engine mounting bracket.
7. Remove engine mount from crankcase.
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Removing engine support
Note: Remove engine support only if necessary. Make sure that supports are not stressed by engine.
1. Remove screws and washers from engine support ( Page 1639).
2. Remove engine support from crankcase.
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9.16.4 Engine mount Cleaning
WARNING
Compressed air.
Risk of injury!
Engine mount Cleaning
Note: Do not allow resilient rubber mounts to come into contact with oil and fuel.
1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Blow out all parts thoroughly with compressed air.
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9.16.5 Engine mounts Check
Material
Spare parts
Engine mounting bracket
Damper mount
Dowel pin
Checking engine mounts
Check engine mounting bracket for cracks
with red penetrant dye.
Using the magnetic crack-testing method,
check central buffer for cracks.
Check central buffer for wear and damage. Traces of wear
Damage
Visible
Replace
Check resilient rubber mounts for cracks and
deformation (visual inspection).
Damage
Cracks
Deformation
Visible
Replace
Check thread for ease of movement. Sluggish Rework: recut thread.
Replace
Check bolt-on faces for flatness. Uneven Rework: smooth with oilstone.
Replace
Check grooves for O-rings for damage. Damaged Rework
Replace
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9.16.6 Engine mount Installation
Special tools
Material
Engine oil
Spare parts
O-ring
DANGER
Danger to life!
DANGER
Suspended load.
Danger to life!
DANGER
Installing engine supports
1. Install engine supports with screws and washers as shown in overview drawing ( Page 1639).
2. Tighten screws and washers of engine supports.
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A Marking 30 = 6.0 mm buffer clearanceMarking 40
= 8.0 mm buffer clearance
B Unloaded 152.5 mm
C Serial number
D Shore hardness
E Type
F Unloaded 50 mm
G Initial dimension 5 mm
Installing engine mounting bracket with resilient
mount
Note: The resilient mounts are supplied in
preadjusted and locked condition.
1. Prior to installation, check presettings of resilient
mounts. Readjust if required.
2. Degrease engine mounting bracket (3) and flange
mating face (1).
4. Insert O-ring (2) in groove.
5. Chill dowel pins (arrows) in liquid nitrogen.
6. Press dowel pins (arrows) into engine mounting
bracket.
7. Use depth gauge to measure and check blind
hole in crankcase.
Result: Protrusion of dowel pin in engine mounting
bracket must not be greater than depth of blind
hole.
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8. Install assembly pins (1).
9. Mount engine mount on engine mounting bracket
(2).
10. Tighten nut manually.
11. Install engine mounting bracket (2) with screws (3)
and washers as shown in overview drawing
( Page 1639).
12. Use torque wrench to tighten screws to specified
13. Remove assembly pins (1).
14. Align base mounts of resilient mounts in
longitudinal direction.
15. Loosen screws on engine supports.
16. Lower engine on to foundation by turning all
jackscrews alternately and evenly.
17. Back off jackscrews.
18. Remove locking screws (6), washers (5) and nuts
(4) or jackscrews and store somewhere safe.
19. Check engine alignment (Height adjustment ).
20. Screw bearing element on to foundation.
21. Use feeler gauge to measure buffer clearance on
resilient mount through measuring groove (3),
readjust central buffer if required.
23. Prevent central buffer from turning by holding
hexagon (1) firmly in place.
Note: Make sure that no oil drips on to rubber
mount.
24. Coat nut mating face and threads of central
buffer with engine oil.
25. Shut down the engine with the locking screws
released for at least 48 hours.
Result: The rubber mounts are compressed.
26. Measure height and height angle.
Result: The dimensions of the shims required to
be installed under the relevant base mount are
defined.
27. After flanging the engine with alternator or
gearbox, align the unit in longitudinal and
transverse direction in accordance with the
alignment instructions.
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A Model RD 314 B 3 mm +0.3 mm
A Model RD 315 HD 4 mm +0.3 mm.
Adjusting central buffer
Note: Target measured values with locking
system removed and engine filled with
engine coolant and engine oil.
1. Remove protective cap and loosen nut.
2. Screw central buffer clockwise into upper stop
position.
3. Unscrew central buffer counterclockwise by the
dimension of clearance (A).
4. Check clearance with feeler gauge through
measuring groove in base mount.
5. Use torque wrench to tighten nut to specified
6. Fit protective cap.
Height adjustment
1. Remove protective cap (1) and release nut (2).
Note: Make sure not to twist central buffer.
2. Lock bearing cap by fitting a locking screw (4).
3. Using height adjusting nut (3), adjust height by
max. 10 mm.
4. If the required height adjustment is still not
achieved, adjust the height by using shims under
the base mount (5).
5. Tighten nut (2) and protect central buffer from
twisting.
6. Seal protective cap and remove locking screw.
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9.17 PTO Systems, Driving End and Free End (Coupling)
9.17.1 Geislinger steel-spring coupling Removal
Special tools
Adjusting mandrels F30379307 2
WARNING
Heavy object.
Risk of crushing!
Removing steel-spring coupling
1. Mount positioning fixture (1) on flywheel.
2. Depending on the position of the steel-spring
coupling, remove screws (2) for lifting device.
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3. Fit lifting device (2) on steel-spring coupling (1)
and attach to crane with a lightly tensioned rope.
4. Remove screws (1) from steel-spring coupling (2)
to flywheel (3).
5. Screw in adjusting mandrels (1).
6. Remove both screws (2) for forcing thread.
7. Install removal device.
8. Using removal tool, force steel-spring coupling off
flywheel.
9. Place steel-spring coupling on a suitable surface.
10. Remove O-rings.
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9.17.2 Geislinger steel-spring coupling Disassembly
WARNING
Heavy object.
Risk of crushing!
Remove Geislinger steel-spring coupling ( Page 1649).
Geislinger steel-spring coupling Disassembly
1. Place steel-spring coupling (1) on flange of inner
star.
2. Remove sealing ring screws (2).
3. Press sealing ring (3) with two sealing ring screws
(2) off forcing thread (4) and remove.
4. Turn over steel-spring coupling and place coupling
intermediate section on wooden blocks.
5. Remove hex screws (3).
6. Remove inner star (1) with split bearing and
bearing retainer (4).
7. Raise bearing retainer (4) in direction inner star (1).
8. Remove split bearing by radially withdrawing
the bearing shells.
9. Remove bearing retainer (4) from inner star (1).
10. Remove retaining screws (2) from coupling
intermediate section.
11. Raise side plate from intermediate element spring
unit.
Result: This arrangement permits a complete
inspection of the steel-spring coupling.
Further disassembly is permitted only at the
manufacturers or at a Geislinger Service Point.
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9.17.3 Steel-spring coupling Cleaning
Material
Cleaning agent
Diesel fuel
WARNING
Do not smoke.
WARNING
Compressed air.
Risk of injury!
CAUTION
Steel-spring coupling Cleaning
4. Treat parts with diesel fuel to protect against corrosion.
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9.17.4 Geislinger steel-spring coupling Check
Spare parts
Steel-spring coupling
WARNING
Heavy object.
Risk of crushing!
Clean Geislinger steel-spring coupling ( Page 1652).
Geislinger steel-spring coupling Check
Item Findings Task
Check bearing running surfaces for
abrasion.
Abrasion visible Replace damaged parts.
Contact Geislinger or a
Geislinger Service Point.
Check bearing clearance from inner
star to bearing bush and sealing
ring.
Sluggish Recondition: Recut threads.
Replace
Wear test for spring leaves
X max. permissible wear = 2.4 mm
Note: Wear or deformation of the bronze packing
pieces located between the spring leaves
is perfectly normal.
1. Check max. permissible wear X per side of the
inner end of the centre leaf.
2. If wear exceeds the max. permissible wear
dimension X, have all spring packs replaced by
Geislinger or a Geislinger Service Point.
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Wear test for inner star
A max. permissible wear = 1 mm
1. Check maximum wear of groove flanks.
2. If wear exceeds max. permissible dimension A,
replace inner star or recondition groove flank.
Contact Geislinger or a Geislinger Service Point.
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9.17.5 Geislinger steel-spring coupling Assembly
Material
Engine oil
Lubricating grease
Spare parts
Dished washer
O-rings
WARNING
Heavy object.
Risk of crushing!
CAUTION
Check Geislinger steel-spring coupling ( Page 1653).
Geislinger steel-spring coupling Assembly
1. The procedure is the same disassembly but in reverse sequence.
2. The following additional instructions must be observed.
2.1. Replace all sealing elements.
2.2. Replace all dished washers.
2.3. Coat bearings and bearing running surfaces with lubricating grease.
2.4. Coat O-rings with petroleum jelly.
2.5. Insert O-rings in grooves.
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9.17.6 Geislinger steel-spring coupling Installation
Special tools
Material
Spare parts
O-ring
WARNING
Heavy object.
Risk of crushing!
CAUTION
CAUTION
Assemble Geislinger steel-spring coupling ( Page 1655).
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Installing Geislinger steel-spring coupling
1. Degrease and dry-clean flanging surfaces and
centering devices.
2. Screw adjusting mandrels (1) on to flywheel (2).
4. Insert O-ring (3) in flywheel.
6. Insert O-ring (1) in groove of steel-spring coupling.
7. Prior to installation, ensure positioning pin (2) is
correctly positioned in relation to flywheel.
8. Install lifting equipment (2) with support bracket on
9. Attach steel-spring coupling (1) and lifting
equipment (2) to crane with a lightly tensioned
rope.
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10. Use crane to position steel-spring coupling (3) on
flywheel (1) and slide on to adjusting mandrels (2).
11. Place entire steel-spring coupling (3) on
flywheel (1).
12. Screw in steel-spring coupling (3) diagonally with
4 screws and dish washers without Loctite 270.
13. Tighten screws to specified tightening torque using
a torque wrench ( Page 980).
14. Remove lifting equipment with support bracket
from steel-spring coupling (3).
15. Install positioning fixture(1) on flywheel (2).
16. Apply Loctite 270 to both sides of dish washers
for screws (3).
17. Insert 8 screws (3) with dish washers in
18. Tighten opposing screws (3) to specified tightening
19. Remove the 4 assembly screws.
20. Coat both sides of dish washers for assembly
screws with Loctite 270.
21. Tighten opposing screws to specified tightening
22. Coat both sides of dish washers for slotted
screws (1) with Loctite 270.
23. Insert slotted screws (1) in lifting thread bores
and tighten to specified tightening torque using a
torque wrench ( Page 980).
24. Remove positioning fixture.
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9.17.7 Diaphragm coupling Overview
Diaphragm coupling
1 Diaphragm coupling
2 Screw
3 Washer
4 Washer
5 Washer
6 Screw
7 Screw
8 Washer
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9.17.8 Diaphragm coupling Removal
DANGER
Electrical voltage.
DANGER
Suspended load.
Danger to life!
Diaphragm coupling Removal
1. Secure generator with rope and crane.
2. Remove guard plates from flywheel housing.
3. Remove screws (2) and (7) with washers (8) as per overview drawing ( Page 1659).
4. Carefully separate generator from engine.
5. Remove screws (6) as per overview drawing ( Page 1659).
6. Remove diaphragm coupling.
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9.17.9 Diaphragm coupling Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove diaphragm coupling ( Page 1660).
Diaphragm coupling Cleaning
1. Clean diaphragm coupling with cleaner.
2. Remove cleaner.
3. Rub diaphragm coupling dry with cloth.
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9.17.10 Diaphragm coupling Check
Material
Spare parts
Diaphragm coupling
Washer
WARNING
Heavy object.
Risk of crushing!
Clean diaphragm coupling ( Page 1661).
Diaphragm coupling Check
Visually inspect all components for damage
and deformation.
Damaged, deformation visible Replace
Check varnish coat of diaphragm coupling for
damage.
Damaged Replace
Replace
Check diaphragm coupling with red penetrant
dye for cracks.
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9.17.11 Diaphragm coupling Installation
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury danger to life!
Take special care when working on a running engine.
WARNING
Heavy object.
Risk of crushing!
Check diaphragm coupling ( Page 1662).
Installing diaphragm coupling on generator shaft
Measurement values table
= (pressed + pulled) / 2
X (engine) Y (generator)
No. pressed pulled pressed pulled
1
2
Mean value
1. Fit diaphragm coupling on generator shaft.

2. Install 4 screws (M16 x 60) offset 90 and tighten
crosswise and evenly to specified tightening
torque ( Page 980).
pressed.
pressed.
position.
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12. Measure dimension X with crankshaft pressed.
14. Measure dimension X with crankshaft pulled.
position.
Note: If necessary, disassemble diaphragm
coupling and correct dimension Y by
means of adjusting shims.
21. Check result (specified value Y = X -0.2 to -0.5).
22. Screw in remaining screws (M16 x 60) and tighten
23. Replace angular plates in generator fan gap with
more easily detachable shims (1).
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24. Screw 2 guide pins (1) into diaphragm coupling
and into flywheel housing and tighten.
Installing generator housing on flywheel housing
1. Secure generator housing (2) with rope (1) and
crane.
2. Join generator housing to flywheel housing (3) and
diaphragm coupling (4) into flywheel, positioning
by means of guide pins (arrow).
3. Fit generator housing screws (M12 x 40).
4. Tighten 2 screws simultaneously, or, if not possible,
then alternately in stages of 30 angle of rotation,
5. Remove guide pins, replace with screws (M12 x
40) and tighten.
6. Support genset on generator side at bearing points.
7. Detach starter from crane.
8. Remove shims from generator fan gap.
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Installing diaphragm coupling with generator shaft
on flywheel
1. Insert screws (1) (M16 x 40) via flywheel housing
openings.
2. Replace guide pins with screws.
3. Tighten 2 opposite screws simultaneously to
4. Use a suitable tool to rotate crankshaft further via
flywheel housing opening until all screws have
been pretightened.
5. Tighten screws, again diagonally and evenly or
alternately in stages of 30 angle of rotation, to
specified tightening torque ( Page 980) .
Concentricity check
Note: If concentricity is above 0.13 mm, remove generator and repeat installation with new installation
position of flywheel and coupling.
1. Measure concentricity of diaphragm coupling (max. permissible 0.13 mm).
2. Note measured values.
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9.17.12 Auxiliary PTO, lateral Overview
Auxiliary PTO, lateral
1 Cover
2 O-ring
3 Screw
5 Gear
6 Housing
7 Screw
8 Washer
9 Sealing ring
10 Flange
11 Guard plate
12 Screw
13 Washer
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Auxiliary PTO externally mounted components
1 Flange
2 Cover
3 O-ring
4 Washer
5 Screw
6 Retainer
7 Screw
8 Washer
9 Screw
10 Washer
11 Plate
12 Retainer
13 Screw
14 Washer
15 Screw
16 Washer
17 Screw
18 Washer
19 Coupling
20 Screw
21 Washer
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Arrangement of installation/removal device for auxiliary PTO flange
1 Connection, SKF oil pressure
hand pump
2 Thrust sleeve
3 Bush
4 Removal/installation device
5 Draw spindle
6 Flange
7 Housing
A Reference dimension = 185 mm
B Push-on dimension = 5.1mm
7.5mm (measured from inner face
of flange to face of gear shaft).
C Check surface = Press-fitted flush
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9.17.13 Auxiliary PTO Removal
Special tools
Installation/removal device, hydraulic pump drive flange F0140044 1
Hydraulic hand pump, 0-3000 bar F6557936 1
WARNING
Removing auxiliary PTO
1. Remove hydropump and coupling with externally
mounted components as shown in the overview
2. Screw draw spindle (3) into flange (2).
3. Install installation/removal device.
4. Screw hydraulic HP fuel line (5) into flange.
5. Install nut (4) and fit by hand.
6. Vent oil pressure hand pump and pipework until
bubblefree oil emerges.
7. Connect HP line to oil pressure hand pump.
8. Read off maximum expansion pressure P
max
at flange.
9. Operate hydraulic hand pump for expanding the
flange taper until expansion pressure is half the
permitted maximum.
10. Maintain this pressure for approx. 5 minutes.
11. Raise expansion pressure in stages of 0.1 x P
max
,
observing holding times of approx. 2 minutes.
Ensure that P
max
is not exceeded.
12. Slowly back off nut (4) until flange (2) is completely
released from shaft.
13. Release hand pump pressure and unscrew
HP line.
14. Remove installation/removal device and draw
spindle.
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15. Remove flange from shaft.
16. Remove housing (1 in the overview drawing
( Page 1667)).
Removing shaft with gear
1. Press gear shaft (5 in the overview drawing ( Page 1667)) from fit and remove.
2. Unscrew all screws (3 in the overview drawing) from cover (1 in the overview drawing) and remove cover.
3. Press sealing ring (9 in the overview drawing) from fit and remove.
4. Use a suitable puller to remove cylindrical roller bearing (4 in the overview drawing) from shaft.
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9.17.14 Auxiliary PTO Cleaning
Material
Cleaner
WARNING
Compressed air.
Risk of injury!
CAUTION
Remove auxiliary PTO ( Page 1670).
Auxiliary PTO Cleaning
1. Clean all parts with cleaner.
2. Remove cleaner.
3. Blow clean all parts thoroughly with compressed air.
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9.17.15 Auxiliary PTO Check
Material
Fluorescent magnetic powder for magnetic crack-testing method
Spare parts
Cover
Gear
Housing
Flange
Guard plate
Bracket
Plate (optional)
Coupling
Clean auxiliary PTO ( Page 1672).
Checking auxiliary PTO
Item Findings Task
Using the magnetic crack-testing method and
fluorescent magnetic powder, check housing,
shaft and gear for cracks.
Visually check sealing surfaces, annular
grooves on cover, flange and housing for wear,
Damaged Reconditioning:
Smooth with emery
cloth or oilstone.
Replace
Check shaft with gear for wear and damage. Slight wear
Damage
visible
Reconditioning:
Smooth with emery
cloth or oilstone.
Replace
Measure bearing seats on shaft with
micrometer.
Limit values exceeded Replace
Visually inspect cylindrical roller bearing
for damage. Always replace during major
overhaul.
Damaged Replace
Check coupling visually for wear and damage. Heavy wear, damage visible Replace
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9.17.16 Auxiliary PTO Installation
Special tools
Installation/removal device assembly, hydraulic pump drive flange F0140044 1
Hydraulic hand pump 0-3000 bar F6557936 1
Draw spindle F6557108 1
Thrust sleeve F6555733 1
Installation tool, radial-lip shaft seal with support F30378655 1
Pressin tool for cylindrical roller bearing 30378656 1
Material
Engine oil
WARNING
Heavy object.
Risk of crushing!
WARNING
Check auxiliary PTO ( Page 1673).
Preparing gear shaft
Note: Bearing inner race and outer race are
seen as a single unit and must not be
interchanged.
1. Coat contact surfaces of shaft (4) and track ring (3)
of cylindrical roller bearing with engine oil.
2. Press-fit track ring (3) of cylindrical roller bearing
with jig (1,2) onto gear shaft (4), ensuring it is
gap-free and correctly positioned.
3. Rotate gear shaft and press-fit track ring of
opposite side accordingly.
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Preparing housing
1. Coat O-ring (2) with petroleum jelly and insert in
groove of housing (3).
2. Coat housing bearing with engine oil.
3. Press-fit cylindrical roller bearing (1) with suitable
tool into housing (3).
4. Turn housing through 180.
5. Clean and degrease housing bore for sealing
ring (1).
6. Press-fit sealing ring (1) so that it is flush with
housing (2).
Installing flange
1. Coat O-ring of cover with petroleum jelly.
2. Install cover (1 in the overview drawing
( Page 1667)) with screws (3 in the overview
drawing).
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3. Coat cylindrical roller bearing (2) with engine oil.
4. Drive cylindrical roller bearing (2) with jig (1)
carefully into housing bore (3).
5. Insert gear shaft (2) up to stop into cylindrical
roller bearing.
6. Position water cock (1) suitably for housing
installation.
7. Screw 2 guide pins (2) into equipment carrier (1).
8. Position housing (3) with small bore (4) down on
guide pins (2).
9. Insert housing (3) via guide pins (2) into equipment
carrier (1).
10. Secure housing with screws.
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11. Coat contact surfaces of flange bore (1) with
engine oil.
12. Fit flange (1) on gear shaft (2) by hand up to stop.
Note: Push-on dimension = 5.1mm 7.5mm,
measured from inner face of flange
(arrowed) to face of gear shaft (arrowed).
13. Push-on dimension check.
14. Install draw spindle (3), thrust sleeve and jig.
15. Connect HP fuel line (5) to flange (2).
16. Vent hand pumps and pipework until bubblefree oil
emerges.
17. Tighten nut (4).
18. Using hand pump, generate expansion pressure
until flange (2) with nut (4) can be easily screwed
on.
19. Do not exceed maximum permissible expansion
pressure.
20. Retain expansion pressure and screw on flange
21. Release expansion pressure.
22. Remove HP fuel line (5).
23. Leave jig approx. 60 mins. at rest.
24. Remove jig, thrust sleeve and draw spindle.
Installing Centa coupling and externally mounted components
1. Install Centa coupling see Special Publication M060715.
2. Install externally mounted components as shown in the overview drawing ( Page 1667).
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9.18 Monitoring and Control System
9.18.1 Monitoring, control and regulation devices Overview
Engine Control Unit (ECU)
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9.18.2 Cabling and engine wiring harnesses Overview
Designation Pin assignment
X2 ECU 4
B1 Camshaft speed
B3 Intake air temperature
B5 Oil pressure
B6 Engine coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
B26 Charge-air coolant temperature
B34 Fuel pressure after filter
B50 Crankcase pressure
F25 Lube oil differential pressure
W2
F46 Leak-off fuel
X3 ECU 4
B33 Fuel temperature
B48 Fuel pressure after HP pump
W3
M8 HP fuel pump actuator
X4 ECU 4
For 8V
For 12V
For 16V
W4
System cable W003
(power supply)
X5 ECU4
System cable W004
(generator control)
X1 ECU4
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1 Wiring harness W2
2 Pressure sensor
3 Pressure sensor
4 Bush
5 O-ring
6 Pressure sensor
7 Pressure sensor
9 Sealing ring
10 Speed sensor
11 Speed sensor
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1 Wiring harness W3 2 Pressure sensor 3 HP fuel pump actuator M8
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A1 Injector Y39.1
A2 Injector Y39.2
A3 Injector Y39.3
A4 Injector Y39.4
A5 Injector Y39.5*
A6 Injector Y39.6*
A7 Injector Y39.7**
A8 Injector Y39.8**
B1 Injector Y39.11
B2 Injector Y39.12
B3 Injector Y39.13
B4 Injector Y39.14
B5 Injector Y39.15*
B6 Injector Y39.16*
X4 Connector to ECU 4
* Only for 12V and 16V
** Only for 16V
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9.18.3 Engine wiring harnesses Removal
Preconditions
Special tools
WARNING
Hot oil.
WARNING
Removing engine wiring harnesses W2 and W3
connector pliers.
sensors/actuators.
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retainers.
7. Carefully remove wiring harness.
Removing engine wiring harness W4
connector pliers.
sensors/actuators.
retainers.
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7. Remove cylinder head covers ( Page 1314).
8. Unscrew spade lugs (1) on injector (2).
9. Undo cable entry (3) and carefully pull connecting
wires out of the cable entry.
10. Remove wiring harness.
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9.18.4 Engine wiring harness Clean
Material
Cleaner (Hakupur 312 at 2% concentration)
CAUTION
CAUTION
Cleaning engine wiring harness
1. Clean engine wiring harness with cleaning agent.
2. Remove cleaner.
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9.18.5 Engine wiring harness Check
Material
Cable tie
Insulating tape
Heat-shrinkable hose
Spare parts
Checking engine wiring harness
1. The engine governor continuously monitors all engine wiring harnesses.
2. The engine governor detects and reports the following errors to the connected monitoring system:
Defective electrical assemblies
Cabling damage
Short circuits
Sensor values outside of the plausibility range.
3. Carry out following checks and maintenance:
cracks, kinks and chafing
Cracks
Kinks
Chafing
visible
Rework: repair using insulating
tape or heat-shrinkable hose.
Replace engine wiring harness.
Check shrink-formed components
for damage.
Damaged Replace shrink-formed components.
Check plug connections for
damages.
Damaged Rework: Straighten plug
connections.
Replace plug connector.
tight seating.
Loose engine wiring harness Re-fix engine wiring harness with
cable tie.
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9.18.6 Engine wiring harnesses Installation
Special tools
Spare parts
Cable clamps/ties
Installing engine wiring harnesses W2 and W3
connected sensors/actuators without tension.
3. Engage and tighten connectors to
sensors/actuators.
4. Press wiring harness into cable retainers.
5. Press locking clips (1) firmly onto cable retainers
until they are fully engaged.
when installing.
6. Secure cables/wiring harnesses (2) with cable
clamps/ties (1).
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Installing engine wiring harness W4
connected injectors without tension.
3. Press wiring harness into cable retainers. Finally
press the locking clips (1) firmly onto the cable
retainers until they engage audibly.
when installing.
4. Secure cables/wiring harnesses with cable
clamps/ties (1).
7. Insert connecting wires in cable entries (3).
8. Twist the wires four times to a suitable length
before connecting them to the injector.
9. Connect spade lugs (1) on injector (2).
10. Install cylinder head cover ( Page 1317).
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9.18.7 Sensors, actuators and injectors Overview
1 F46 (leak-off fuel level) 2 F25 (lube oil differential pressure)
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1 B6 (coolant temperature)
2 B5 (lube oil pressure)
3 B34 (fuel pressure after filter)
4 B33 (fuel temperature)
5 B1 (camshaft speed)
6 B48 (fuel high pressure)
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1 B13 (crankshaft speed) 2 B9 (charge-air temperature) 3 B10 (charge-air pressure)
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1 B50 (crankcase pressure)
2 B7 (lube oil temperature)
3 B26 (charge-air coolant
temperature)
4 B3 (intake air temperature)
The injectors are located below the cylinder head covers. Injector replacement and
necessary activities ( Page 1330).
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9.18.8 Sensors, actuators and injectors Removal
WARNING
Do not smoke.
WARNING
Hot oil.
WARNING
Removing temperature sensors (B3, B6, B7, B9,
B26, B33)
1. Always note:
also identical.
( Page 1690).
2. Observe the following prior to removal:
B6 (coolant temperature) Task description and safety instructions (Operating Instructions)
B7 (oil temperature) During removal, small amounts of engine oil may emerge. Catch engine
oil in a suitable container.
B33 (fuel temperature) During removal, small amounts of fuel may emerge. Catch fuel in a
suitable container.
(2).
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2
9
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9
2
0
0
2
Removing pressure sensors (B5, B10)
1. Always note:
also identical.
( Page 1690).
During removal of sensor B5 (oil pressure),
small amounts of engine oil may emerge. Catch
engine oil in a suitable container.
(2).
1. Always note:
( Page 1690).
During removal of sensor B34 (fuel pressure
after filter), small amounts of fuel may emerge.
(2).
1. Always note:
( Page 1690).
During removal of sensor B48 (fuel high
pressure), small amounts of fuel may emerge.
(2).
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9
2
0
0
2
1. Always note:
( Page 1690).
(2).
Removing speed sensors (B1, B13)
1. Always note:
also identical.
( Page 1690).
2. Release bayonet lock (1) of speed sensor (2) and
remove connector (3) from engine wiring system.
4. Remove speed sensor (2).
Removing differential pressure monitor (F25)
1. Always note:
( Page 1690).
During removal of sensor F25, small amounts of
engine oil may emerge. Catch engine oil in a
suitable container.
2. Release screw (1) of connector and remove
connector (2).
3. Release nut (3) and screw out sensor (4) from
measuring block (6).
4. Remove copper sealing ring (5).
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0
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2
9
6
9
2
0
0
2
Removing level probe (F46)
1. Always note:
( Page 1690).
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0
0
0
0
2
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9
2
0
0
2
9.18.9 Sensors, actuators and injectors Check
Material
Isopropyl alcohol
Spare parts
Pressure sensor
Pressure monitor
Speed sensor
Temperature sensor
Level monitor
Sensors, actuators and injectors Check
1. Always note:
The governor is able to detect defective electric assemblies, wire breaks, short circuits and deviating
sensor values.
2. Carry out the following checks:
Item Findings Task
Check sensors and actuators for
secure seating.
Loose sensors or actuators. Retighten securing screws.
Check security of plug connections. Loose plug connections. Connect plug connections properly
and tighten.
Check sensors, actuators and
plug connections for mechanical
damage.
Damaged Replace
Check sensors, actuators and plug
connections for contamination (e.g.
oil sludge).
Contamination visible. Clean relevant assembly with
isopropyl alcohol.
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3
7
0
0
1
9.18.10 Sensors, actuators and injectors Installation
Material
Spare parts
O-ring
Sealing ring
Adjusting washer
Check sensors, actuators and injectors ( Page 1698).
Installing temperature sensors (B3, B6, B7, B9,
B26, B33)
1. Always note:
( Page 1690).
Installing pressure sensors (B5, B10)
1. Always note:
( Page 1690).
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1. Always note:
( Page 1690).
1. Always note:
( Page 1690).
1. Always note:
( Page 1690).
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4
0
0
2
1. Always note:
( Page 1690).
3. Determine clearance A see table below. Fit
adjusting washer at installation bore if required.
Clearance A (between sensor and timing wheel)
MDEC 1 mm to 1.3 mm
DDEC 0.5 mm to 1 mm
1. Always note:
( Page 1690).
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0
0
0
0
2
9
6
9
4
0
0
2
Installing differential pressure monitor (F25)
1. Always note:
( Page 1690).
2. Fit new sealing ring (5).
3. Screw in sensor (4) in bore of measurement
block (6) by hand.
5. Fit connector (2) and tighten screw (1).
Level probe (F46)
1. Always note:
( Page 1690).
3. Screw in sensor and tighten nut (1).
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0
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Special Tools 1703
10 Special Tools
10.1 Standard tools Overview
Use
Quan-
tity
8205891159/00 General tool kit 1
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4
0
0
3
10.2 Special tools Overview
Y20010175 Bore gauge, 275-300 mm 1
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0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1705
mm
1
Y20091483 Bore gauge, 160-280 mm 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
mm
1
mm
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1707
Y20091481 Bore gauge, 18-100 mm 1
mm
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y20011268 Dial gauge 1
Y20002779 Depth gauge, 500 mm 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1709
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6783824 Camshaft bearing removal
device
1
B80146893 Hand pump kit 1
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1711
F6557186 Hydraulic screw pretensioner 2
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
main bearing stud
1
F6555771 Stop device for plug (main oil
gallery)
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1713
F6555738 Assembly jig for camshaft
bearing
1
F30378754 Assembly mandrel for end
cover
1
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30450446 Camshaft bearing shrink-on
tool
1
F6555763 Guide bushing for camshaft
bearing shrink-on tool
1
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1715
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6782566 Removal tool for carbon
scraper ring
1
F6557114 Removal tool for cylinder liner 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1717
F6787880 Press-in tool for cylinder liner 1
Y20000326 Micrometer, 150-175 mm 1
Eyebolts
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
T80092075 Eyebolt 4
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1719
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
mm
1
0015890321/00 Retainer 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1721
T80091102 Bracket 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6555724 Support 1
F6557190 Removal tool for main
bearing, driving end
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1723
B80096717 Lukas cylinder 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378426 Installation tool 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1725
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1727
B80146411 Adapter 1
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T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
B80096717 Lucas cylinder 1
F6557191 Press-out tool 1
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T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1729
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30377680 Installation mandrel for
radial-lip shaft seal
1
F6782344 Alignment tool (free end),
equipment carrier
1
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1731
F6557946 Guide bushing for equipment
carrier
1
0005800100000 Eyebolt 1
mm
1
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
mm
1
0015890321/00 Holder 1
Master weights
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1733
mm
1
Y20506341 DynaMIC hardness tester 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y20091482 Bore gauge, 100-160 mm 1
F6553644 Crankshaft locating device 2
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1735
F6783568 Removal tool for crankshaft
bearing caps
1
F6557936 Hydraulic set 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
B80144827 High-pressure hose 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1737
F6553645 Slide protection 2
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1739
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6553649 Installation aid 1
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T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1741
F6553647 Installation/removal device 1
F0140440 ZB Installation/removal tool 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
5505890163/00 SKF hydraulic unit 1
5555890063/00 Hand pump set 1
T80091387 Trestle 1
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T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1743
F6555788 Adapter 1
F30377999 Impact extractor 1
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T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6557134 Assembly sleeve 1
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1745
Y20001744 Micrometer, 175-200 mm 1
F0140771 Installation/removal tool 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1747
F6557187 Flywheel positioning fixture 1
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T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1749
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
T80090748 Hook-ended chain sling (4 off) 1
F0140771 Removal/installation device 1
M020124/02E 2009-02 MTU
T
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1751
T80090748 Hook-ended chain sling
(quadruple branch)
1
F6555766 Barring tool, 8V-16V 1
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T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6783293 Barring tool, 20V 1
F6555791 Barring tool for timing disc 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1753
F6555792 Pointer for barring tool 1
Y4341124 Timing disc, free end 1
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378352 Socket, 22 A/F, conrod screws 1
removal, 8V-16V
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1755
removal, 20V
1
F6559604 Sliding block 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378003 Piston-ring pliers 1
T80091025 Lifting tool for piston 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1757
F6557121 Piston/conrod assembly
sleeves for carbon scraper
ring
1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6555791 Barring device for graduated
disc
1
F6555792 Pointer for barring device 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1759
Y4341124 Graduated disc, free end 1
Y4341919 Measuring equipment for
TDC measurement in cylinder
head
1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378352 Socket A/F 22 conrod
screws
1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1761
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378352 Socket, SW 22 Conrod
screws
1
mm H7
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1763
mm H9
1
mm H7
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
mm H7
1
mm H7
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1765
Y4340442 Check gauge for inlet valve
seat
1
Y4340443 Check gauge for exhaust
valve seat
1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Y4343688 Removal tool 1
Y20000083 C-frame micrometer, 0-25 mm 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1767
B80144872 Plug 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
plugs
1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1769
F6783833 Valve spring compressor 1
F30377634 Socket 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6783749 Tool kit without elliptical
1
F6783751 Tool kit (accessory
equipment) for elliptical
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1771
F6784421 Tool kit for valve-seat insert
removal
1
F30450433 Indexable insert 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6554300 Mounting plate for valve guide
installation
1
F30450348 Valve guide extractor 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1773
F6781747 Valve guide mandrel 1
0 cylinder head bore
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
I cylinder head bore
1
II cylinder head bore
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1775
tool for exhaust valve with
valve-seatinsert
1
tool for inlet valve with
ellipticalchamfer and
with/without valve-seat
insert
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
8205890451/00 Turning handle for valve seat
contour restoring tool
1
Y4340443 Exhaust valve gauge 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1777
Y4340442 Inlet valve gauge 1
Y4341935 Valve seat test device 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30451554 Countersink reamer tool 1
valve-seat insert, inlet
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1779
valve-seat insert, exhaust
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
seal plug
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1781
B80144872 Seal plug 1
F6553658 Tightening tool (power
amplifier)
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6558582 Alignment tool for 8V and 12V
cylinder heads
1
F6553648 Alignment tool for 16V and
20V cylinder heads
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1783
Y20044010 Measuring tool for angle of
rotation
1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F30378617 Mandrel, 20 mm 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1785
F30377862 Guide sleeve for mandrel 1
F30271842 Mandrel, 24 mm 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
F30377635 Mandrel, 30 mm 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1787
Y20506341 Hardness tester DynaMIC 1
0015890321/00 Measuring stand 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6553642 Camshaft locating device 1
F30450435 Camshaft installation/removal
tool
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1789
8V-16V
1
20V
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
driving end
1
driving end
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1791
free end
1
F6780582 Centering sleeve for assembly
on free end
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
driving end
1
driving end
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1793
free end
1
F6780582 Centering sleeve for
free end
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1795
Y20010128 Feeler gauge 1
Y4341124 Graduation plate, free end 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1797
8205893261/00 Oilstone 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
T80091799 Lifting equipment for HP
pump
1
0005388520 Hot-air gun 1
M020124/02E 2009-02 MTU
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0
0
0
0
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1
Special Tools 1799
0135315483 Connector pliers 1
M020124/02E 2009-02 MTU
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0
0
0
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6
0
0
0
0
1
F30377769 Puller 1
F6557991 Puller bracket 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1801
F6555197 Lever 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
F6557952 Force-in lever 1
F30373588 Crowfoot box wrench for HP
lines
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1803
F6553674 Retaining device for HP
accumulator installation
1
F6557185 Alignment tool for HP
accumulator
2
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
F30379005 Slotted nut screwdriver 1
F30379104 Filter wrench 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1805
F70144375 Vibe jaw 2
F30520703 T torque wrench 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
F70144375 Assembly jaws 2.
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1807
F30520703 Tee torque wrench, 10-90 Nm 1
Y20044010 Angle of rotation measuring
device
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Y20504961 Dynamometer 1
M020124/02E 2009-02 MTU
T
I
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1809
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Test bath
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1811
B80090843 Eyebolt 2
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1813
F6781539 Hydraulic spindle 1
F6780562 Puller tool for impeller 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6780561 Puller tool for gear 1
F6781573 Holding fixture 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1815
F30275611 Carrier for several mandrels 1
F30379316 Press fit tool 1
M020124/02E 2009-02 MTU
T
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0
0
0
0
0
0
9
6
0
0
0
0
1
F30378152 Press fit tool for
angular-contact ball bearings
1
F30378153 Press fit tool for ball bearings 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1817
F30378550 Press fit tool for shaft seal 1
F30378151 Press fit tool for rotary seal 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
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9
6
0
0
0
0
1
F6780563 Support for bearing housing 1
F6781573 Support for shaft with bearing 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
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9
6
0
0
0
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1
Special Tools 1819
F6780561 Retaining device 1
Cleaning brush
5505890531/00 Retaining device 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F6781573 Seat for shaft with bearing 1
000580010000 Eyebolt 2
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1821
F30379297 Driving mandrel 1
F6782572 Retaining jig 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
F6557187 Positioning fixture 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1823
F30379609 Box wrench 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
F30379307 Adjusting mandrels 2
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1825
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
6
0
0
0
0
1
F0140044 Installation/removal device,
hydraulic pump drive flange
1
F6557936 Hydraulic hand pump,
0-3000 bar
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
Special Tools 1827
F0140044 Installation/removal device
assembly, hydraulic pump
driveflange
1
F6557936 Hydraulic hand pump
0-3000 bar
1
F6557108 Draw spindle 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
6
0
0
0
0
1
F6555733 Thrust sleeve 1
F30378655 Installation tool, radial-lip
shaft seal with support
1
30378656 Pressin tool for cylindrical
roller bearing
1
M020124/02E 2009-02 MTU
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0
0
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0
0
9
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1
Special Tools 1829
10.3 General workshop equipment Overview
Use
Quan-
tity
F30004455 Open-end wrench 1
F30006068 Double open-end
wrench
1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
2
1
6
0
0
2
Use
Quan-
tity
bit
1
bit
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
2
1
6
0
0
2
Special Tools 1831
Use
Quan-
tity
bit
1
bit
1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
2
1
6
0
0
2
Use
Quan-
tity
F30047446 Torque wrench 1
F30450902 Ratchet bit 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
2
1
6
0
0
2
Special Tools 1833
Use
Quan-
tity
F30501631 Starter wrench 1
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
2
1
6
0
0
2
Use
Quan-
tity
5505890921/00 Compression
pressure recorder
1
5505890921/06 Diagram sheets 1
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
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1
6
0
0
2
Special Tools 1835
10.4 Measuring tools General overview
Use
Quan-
tity
M020124/02E 2009-02 MTU
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:
0
0
0
0
0
0
9
2
1
5
0
0
2
Use
Quan-
tity
Y20000665 Adjusting ring
(9 mm)
1
Y20000918 Depth gauge 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
2
1
5
0
0
2
Special Tools 1837
Use
Quan-
tity
Y20001743 Caliper gauge 1
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
2
1
5
0
0
2
Use
Quan-
tity
M020124/02E 2009-02 MTU
T
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:
0
0
0
0
0
0
9
2
1
5
0
0
2
Special Tools 1839
Use
Quan-
tity
M020124/02E 2009-02 MTU
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0
0
0
0
0
0
9
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5
0
0
2
10.5 Tools kits Overview
Part No. Designation
Use
Qty.
F30378882 W4 tool kit for Series
4000
1
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Annex 1841
Annex
11 MTU Contact/Service Partners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1843
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1842 Annex
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MTU Contact/Service Partners 1843
11 MTU Contact/Service Partners
Service
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and customer
service centers ensure fast and direct support on site and ensure the high availability of our products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For our locally available support, go to MTUs Internet site: http://www.mtu-online.com/mtu/worl/
24h Hotline
With our 24h hotline and flexibility, were your contact around the clock: during the operating
phase, preventive maintenance and corrective operations in case of a malfunction, for information
on changes in conditions of use and for supplying spare parts.
Your contact at Headquarters: Service-support@mtu-online.com
Spare Parts Service
Fast, simple and correct identification of spare parts for your drive system or vehicle fleet.
The right spare part at the right time at the right place.
To this end we offer worldwide networked parts logistics
- a central depot at Headquarters, as well as decentralized depots among our subsidiaries,
representatives and contractual workshops.
Your contact at Headquarters:
e-mail: spare.parts@mtu.online.com
Tel.: +49 7541 908779
Fax.: +49 7541 908102
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Workshop Manual MTU4000R41

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MTU_ValueService

Axial clearance 0.08 0.135

Radial clearance, max. with

Radial clearance, max. with

Axial clearance 0.08 0.135

Radial clearance, max. with

Radial clearance, max. with

1. Fit diaphragm coupling on generator shaft.

Axial clearance 0.08 0.135

Radial clearance, max. with

Radial clearance, max. with

Axial clearance 0.08 0.135

Radial clearance, max. with

Radial clearance, max. with

1. Fit diaphragm coupling on generator shaft.

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