Disassemble/assemble compressor

AR13.30-W-5511B

Disassemble/assemble compressor

8.6.10

21.2.06

Document revised completely.

 

Disassemble/assemble

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.

AS60.80-Z-0001-01A

1

Tilt cab



Notes on tilting the cab

AH60.80-N-0003-01A

2

Remove suction line between air filter housing and intake pipe

3.1

Remove resonance tank (3.1) together using hoses (2.1, 4.1 and 5.1)

Engine 541.9 up to engine end no. 128267

3.2

Remove resonance tank (3.2) together using hose (4.2) and sealing ring (5.2)

Engine 541.9 as of engine end no. 128268

3.3

Remove resonance tank

Engine 542.9

 Counterhold threaded stud.

4

Remove intake pipe at intermediate piece

 Only for engine 541.9.



*BA09.20-N-1001-02C

5

Drain coolant partially

 Installation: Fill with coolant before the engine test run.

AR20.00-W-1142A

6

Remove coolant lines (1, 15 and 19) at cylinder heads with valve intermediate plates (12, 16)



*BA13.30-N-1001-01B

7

Remove compressed air lines (6, 18) at cylinder heads with valve intermediate plates (12, 16)

8

Check compressed air lines (6, 18) and T-connection (17) for carbonization

 If there is carbonization, it is also necessary to check compressed-air line between compressor, compressed air drier and four-circuit protection valve and replace coked parts if necessary.

9

Remove cylinder head with valve intermediate plates (12 or 16)

 Installation: Replace intake valve disks. Only install modified intake valve disks.

Ensure that the roll pins in the valve intermediate plate are correctly positioned.



*BA13.30-N-1005-01B

10

Disassemble/assemble cylinder head with valve intermediate plate (12 or 16)

AR13.30-W-5511-04A



*BA13.30-N-1003-01B



*BA13.30-N-1004-01B



*BA13.30-N-1006-01B



*BA13.30-N-1007-01B



*BA13.30-N-1008-01B



*BA13.30-N-1011-01B

11

Remove soundproofing on frame below

12

Take off end cover at timing case



*BA01.60-N-1001-01B

13

Attach engine cranking device (35) to timing case



*407589006300



*BA01.60-N-1009-01B

14

Remove cylinder liner (13)

 Installation: Observe attached note marking if used cylinder liner (13) is reinstalled and install cylinder liner (13) turned through 90°.

AR13.30-W-7041-02A

*BE13.30-N-1002-01B

*BE13.30-N-1003-01B

*BE13.30-N-1010-01B



*541589003700



*407589006300

15

Remove gasket (14)

 Installation: Replace seal (14).

16

Cover opening on crankcase

17

Turn engine with turning device (35) until corresponding piston pin (21) is accessible



*407589006300

18

Remove securing device (22) with piston ring compressor pliers (32) and pull out piston pin (21)



*541589003700

19

Remove piston (20)

 Installation: From engine end no. 075703 modified pistons (20) with bores in piston ring groove III have been fitted. If piston (20) is replaced, only install this version.

Displace piston ring end gap one after the other by 120° and lubricate piston (20).

20

Remove piston rings at piston (20)

 Check end gap for piston rings; replace piston rings if value not achieved.

AR13.30-W-5511-01A

*BE13.30-N-1004-01B



*000589373700

Feeler gauge

21

Remove timing case cover

 These and all other following operation step are only required if the crankshaft (24), connecting rod (23.1 and 23.2) or bearing flange with bearing bushing (26) are removed / installed.

AR01.40-W-8000A

22

Remove fuel, power steering pump device (28)

AR47.20-W-5712A

23

Remove crankshaft (24)

AR13.30-W-5511-02GB



*BA13.30-N-1013-01B



*442589000300



*541589036300



*407589006300

 Installation: Install crankshaft (24).

AR13.30-W-5511-03GB

*BE13.30-N-1007-01B



*BA13.30-N-1002-01B



*BA13.30-N-1012-01B



*BA13.30-N-1013-01B



*442589000300



*001589532100



*363589022100



*366589002105



*541589036300



Retaining device for installation of dial indicator holder at compressor

WF58.50-W-1330-02G

24

Check stroke and connecting rod journal diameter to crankshaft (24)

 Replace crankshaft (24) if necessary.

*BE13.30-N-1001-01B

*BE13.30-N-1006-01B

25.1

Check inside diameter of bearing bushing with bearing bushing in outer bearing flange (26)

Up to engine end no. 067518

*BE13.30-N-1008-01B

 If worn:



Replace bearing bushing or install new bearing flange with bearing bushing (26).

AR13.30-W-5511-05A



*730589031500

25.2

Check inside diameter of bearing bore in outer bearing flange with bearing bushing (26)

As of engine end no. 067519

*BE13.30-N-1008-01B

 In case of wear, replace bearing flange with bearing bushing (26).

26

Check inner diameter of bearing bore in bearing flange (29)

 If worn:



*BE13.30-N-1013-01B

Replace bearing flange (29).

AR13.30-W-5511-07A



*730589031500



*000589293300



*000589343300

27

Assemble in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

28

Start engine and perform an engine test run

 Continue running engine at idlingspeed until operating temperature is reached and then switch off engine.

29

Check both compressor and all lines for leaks

Visual inspection.

Number

Designation

Engine
541.9, 542.9
with code M32

BE13.30-N-1001-01B

Piston stroke

mm

38

BE13.30-N-1002-01B

Cylinder liner inner dia.

Marking B

mm

100.000 to 100.010

Marking C

mm

100.010 to 100.020

Marking D

mm

100.020 to 100.030

BE13.30-N-1003-01B

Piston outer dia.

Marking B

mm

99.925 to 99.935

Marking C

mm

99.935 to 99.945

Marking D

mm

99.945...99.955

BE13.30-N-1004-01B

Piston ring gap clearance

Grooves I, II, III

mm

0.20 to 0.40

BE13.30-N-1006-01B

Crankshaft connecting rod bearing journal dia.

mm

43.959 to 43.975

BE13.30-N-1007-01B

Crankshaft bearing clearance

Axial

mm

0.150 to 0.250

BE13.30-N-1008-01B

Bearing bush/bearing flange

Inside dia.

mm

38.000 to 38.039

BE13.30-N-1010-01B

Cylinder liner height from timing case

mm

83.8 to 84.0

BE13.30-N-1013-01B

Bearing bushes in timing case

Inside dia.

mm

37.99 to 38.05

Number

Designation

Engine
541.9. 542.9

BA01.60-N-1001-01B

Bolt, end cover of TDC inspection hole to timing case

Nm

25

BA01.60-N-1009-01B

Bolt, engine cranking device to timing case

Nm

25

Number

Designation

Engine
541.9
except code MJ1

Engine
541.9
with code MJ1

BA09.20-N-1001-02C

Bolt, air intake pipe at bracket

Nm

50

60

Number

Designation

Engine
542.9
except code MJ1

Engine
542.9
with code MJ1

BA09.20-N-1001-02C

Bolt, air intake pipe at bracket

Nm

50

60

Number

Designation

Engine 541.9, 542.9

BA13.30-N-1001-01B

Coolant line to compressor

Nm

35

BA13.30-N-1002-01B

Bolt, drive gear at compressor, with special tool

(direct)

Nm

360

(indirect)

Nm

270

BA13.30-N-1003-01B

Screw plug on
compressor cylinder head

M261.5

Nm

80

BA13.30-N-1004-01B

Fitting, coolant line on
compressor cylinder head

M141.5

Nm

35

BA13.30-N-1005-01B

Bolt, cylinder head and cylinder liner at timing case

Stage 1

Nm

20

Stage 2

Nm

40

BA13.30-N-1006-01B

Fitting, compressed air line to compressor cylinder head

M261.5

Nm

80

BA13.30-N-1007-01B

Bolt, valve intermediate plate at compressor cylinder head

Nm

12

BA13.30-N-1008-01B

Bolt of pressure disk valve to valve intermediate plate

Nm

12

BA13.30-N-1009-01B

Bearing flange on timing case

Nm

30

BA13.30-N-1010-01B

Bolt, resonance tank at bracket

Nm

25

BA13.30-N-1011-01B

Fittings for intake air line on
compressor cylinder head

M361.5

Nm

80

BA13.30-N-1012-01B

Bolt, bearing flange to timing case

Nm

60

BA13.30-N-1013-01B

Bolt, blocking device to
timing case

Nm

40

BA13.30-N-1014-01B

Screw plug on
compressor cylinder head

M361.5

Nm

80

BA13.30-N-1015-01B

Banjo bolt, control line to compressor

Nm

15