Changeover to compressor with greater displacement

SM13.30-G-0002B

Changeover to compressor with greater displacement

19.08.2020

Engine

900.915/916, 902.923/924/935, 904.927/928, 906.935/955 in model 405

Engine

900.920/921, 904.952/953, 924.916/923/931 in model 437.4## ## up to 230815

Operation no. of the operation texts or standard texts and flat rates

Category

Op. no.

Operation text

Time

Acc. no.

Code

U

135510

Remove/install compressor (model 405.050 with engine 900.915/916)

90 AW/7,5 h

-

-

U

135510

Remove/install compressor (model 405.1 with engine 900.915/916, 904.927/928)

86 AW/7,2 h

-

-

U

135510

Remove/install compressor (model 405.1/2 with engine 902.923/924/935, 906.935/955)

72 AW/6,0 h

-

-

U

135510

Remove/install compressor (MODEL 437.42/43/465 with ENGINE 900.920/921, 904.952/953, 924.916/923/931)

53 AW/4,4 h

-

-

1

Compressor

2

Screw

3

Coolant line

4.1

Elbow fitting

4.2

Threaded fitting

5

Compressed-air line

6

Coolant line

B16

TDC sensor ­ for cylinder 1

5

Compressed-air line

7

Control line

8.1

Ball

8.2

Union nut

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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

Topical note

Notes on coolant

AH20.00-N-2080-01A



Check

1

Check exceptions for conversion.

 Model 405 with engine 902.935, 906.935/955 and power hydraulics code H63/64/65 in combination with code H93 or H94
The collision of the compressor cylinder head (1) with the hydraulic line means it is not possible to convert it.

 MODEL 437.42/43 up to vehicle identification end number 211454 with ENGINE 904.952/953, 924.916
The collision of the compressor coolant line (1) with the cab floor means it is not possible to convert it.

 

Remove/install

2

Charge the compressed air system up to shutoff pressure.

3

Switch off ignition.

4.1

Tilt cab to repair position.

Model 405, model 437.42/43



AR60.80-G-0005B

4.2

Open hood.

Model 437.465

 See information from body manufacturer.

5

Check return flow valve in the pressure regulator for the air drier for leak tightness.



Model 405, model 437.42/43/465

AR42.60-G-0025B

6

Remove MR (PLN) control unit (A6).



Only for engine 900, 904, 924

AR07.15-G-1628B

 Only for engine 900.915/916, 904.927/928 in model 405 with code H93 (Front pressure and return line, hydraulic circuit 3) with code M55 (Fuel preheating, with water separator) with compressor 393 cm3 displacement or with code H94 (Front pressure and return line, open circuit) with code M55 (Fuel preheating, with water separator) with compressor 393 cm3 displacement
Installation: Retrofit protective hose to fuel line.

If the protective hose needs to be retrofitted,



retrofit protective hose to fuel line.



Engine 900.915/916, 904.927/928 in model 405

AN47.25-G-0001B

7

Remove power steering pump.



Engine 900, 902, 904, 906 in model 405

AR46.30-G-0500B



Engine 900, 904, 924 in model 437.42/43/465

AR46.30-G-0500C

8

Unfasten all retaining clamps on coolant pipe and fix coolant pipe in place upwards.

Only for engine 900, 904 in model 405

 On coolant pipe above the compressor (1).

9

Remove retaining clamp for control line (7) from compressed air line (5).

Engine 900.915/916, 902.923/924 in model 405 with compressor 352 cm3 displacement, engine 900.920/921, 924.923/931 in model 437 with compressor 352 cm3 displacement

 Installation: When converting to the compressor (1) with 393 cm3displacement the control line (7) is no longer required.

10

Remove control line (7) up to the connecting point.

Engine 900.915/916, 902.923/924 in model 405 with compressor 352 cm3 displacement, engine 900.920/921, 924.923/931 in model 437.4 with compressor 352 cm3 displacement

 Installation: When converting to the compressor (1) with 393 cm3 displacement the control line (7) is no longer required.
Close off the connection for the connecting point with a ball (8.1) and union nut (8.2).
Bind the line remaining in the vehicle with cable tie on the frame.

11

Slowly open cap on coolant expansion reservoir and then close it again.

 In order to reduce the overpressure in the engine cooling system.

12

Remove coolant line (3) from compressor cylinder head (1) and collect escaping coolant.

 The cap on the coolant expansion reservoir must not be opened.

 Installation: Install new sealing rings.

 Banjo bolt, coolant line to compressor

*BA13.30-N-1004-01I

13

Close off coolant line (3), as shown, with screw/bolt, sealing rings and nut.

14

Remove coolant line (6) from compressor cylinder head (1) and collect escaping coolant.

 Installation: Install new sealing rings.

 Only on engine 904.927/928, 906.935/955 in model 405 with compressor 238 cm3 or compressor with optimized cylinder head (A 001 130 79 15)
Installation: The coolant line (6) must be replaced with a slightly shorter version.

 Banjo bolt, coolant line to compressor

*BA13.30-N-1004-01I

15

Remove retaining clamp of compressed-air line (5).

16

Remove the elbow fitting (4.1).

 Installation: When tightening the elbow fitting (4.1), counterhold the threaded fitting (4.2) against it.

17

Remove air intake duct from compressor (1).

 Only for engine 902, 906 in model 405
Installation: A resonator must be retrofitted.

 Only on engine 902, 906 in model 405 up to vehicle identification end number 218033
Installation:
In order to install the resonator, the existing air intake pipe must be replaced by an air intake hose (for part number, see the parts ordering note).

If a resonator has to be retrofitted,



retrofit a resonator box.

engine 902, 906

SM13.30-G-0004-01B

18

Remove TDC sensor ­ for cylinder 1 (B16) from timing case and seal opening.

Only for engine 900, 904, 924

 Do not disconnect electrical connection.

 Installation: Press in the TDC sensor ­ for cylinder 1 (B16) up to the end stop.

19

Remove holder and retaining clamp of hydraulic lines from frame at bottom.

Only for engine 900, 904 in model 405

 In the area of compressor (1).

20

Remove compressor (1) from crankcase.

 Installation:
If the compressor (1) with 393 cm3 displacement is installed, the outer upper screw (2) M10x40 must be replaced by a shorter screw (2) M10x25.
The compressor (1) will not be fastened appropriately otherwise.

 A suitable tool for removal/installation of the screws (2) from the compressor (1) with 393 cm3 displacement can be ordered on the Internet at http://www.snapon.com.
Adapter 3/8" to 1/4"
(Order no. GFAT1E),
1/4" extension 50 mm
(Order no. TMXWK2),
1/4" extension 100 mm
(Order no. TMXWK4),
1/4" extension 150 mm
(Order no. TMXWK60),
1/4" ball joint Torx socketE12
(Order no. TSE120).

 Collect escaping engine oil.

 Installation: First tighten inner upper screw (2), then tighten remaining screws (2).

 Screw/bolt, compressor to crankcase

*BA13.30-N-1006-01I

21

Remove compressor (1).

 Installation: replace O-ring. Check O­ring is correctly seated.

22

Remove the threaded fitting (4.2).

 Installation: Replace sealing ring.

 Threaded fitting, compressed-air line to compressor

*BA13.30-N-1007-01I



Check

23

Check the elbow fitting (4.1), threaded fitting (4.2) and air line (5) for carbonization.

If problems are found,



Replace carbonized components.

24

Check air intake duct on compressor (1) for damage.

If problems are found,



Replace air intake duct.

25

Install in the reverse order.

26

Retrofit pressure limiting valve in compressed air system.

Only on engine 900.915/916, 902.923/924/935, 906.935 in model 405.050/101/103/121/123/201/221 up to vehicle identification end number 227666



Service Information: Install additional pressure limiting valve in high-pressure control circuit of compressed air system

MODEL 405.050/101/103/121/123/201/221 up to vehicle identification end number 227666

SI42.60-G-0011A



Model 405.050/101/103/121/123/201/221 up to vehicle identification end number 227666 with code A54 (Preparation for auxiliary rear axle steering)

AN42.60-G-0014B



Model 405.050/101/103/121/123/201/221 up to vehicle identification end number 227666 with code A54 (Preparation for auxiliary rear axle steering)

AN42.60-G-0014BB



Check

27

Check engine oil level at electric display.

 See owner's manual.

If problems are found,



Correct engine oil level .

28

Correct coolant level.



ENGINE 900, 902, 904, 906 in MODEL 405

AP20.00-G-2010B



Engine 900, 904, 924 in model 437.4

AP20.00-G-2010C

29

Purge engine cooling system.



Only for engine 900, 902, 904, 906 in model 405

AR20.00-G-1040B

30

Check engine cooling system for leak tightness.

 Visual inspection.

31

The compressor (1), compressed-air line (5), connecting point of control line (7) and the power-steering pump for leak tightness.

Update Vehicle Documentation (VeDoc)

32

Document new SAA Z505.018/21 and "Conversion to compressor (1) with 393 cm3 displacement" note in VeDoc.

 Cost settlement: A warranty/goodwill claim can be submitted for the operation/parts expense depending on the operating data. Damage code: 13001 ZZ

33.1

Delete previous SAA Z505.018/08 in VeDoc.

Engine 902.935, 904.927/928, 906.935/955 in model 405 with compressor 238 cm3 displacement, engine 904.952/953, 924.916 in model 437.4 with compressor 238 cm3 displacement

33.2

Delete previous SAA Z505.018/07 or Z505.018/09 in VeDoc.

Engine 900.915/916, 902.923/924 in model 405 with compressor 352 cm3 displacement, engine 900.920/921, 924.923/931 in model 437.4 with compressor 352 cm3 displacement

 Compressor (compressed air system)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA13.30-N-1004-01I

Banjo bolt, coolant line to compressor

Nm

40

 Compressor (compressed air system)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA13.30-N-1006-01I

Screw/bolt, compressor to crankcase

Nm

50

 Compressor (compressed air system)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA13.30-N-1007-01I

Threaded fitting, compressed-air line to compressor

Nm

100

Parts ordering note

Part no.

Designation

Quantity

Code explanations: code H93 (Front pressure and return line, hydraulic circuit 3); code H94 (Front pressure and return line, open circuit); code M55 (Fuel preheating, with water separator)

A 000 821 06 97

Protective hose 1 m (only with engine 900.915/916, 904.927/928 with code H93 or code H94 with code M55 with compressor 393 cm3 displacement)

1

A 002 997 24 90

Cable tie (290 mm to 310 mm, attachment of protective hose to fuel line) (only with engine 900.915/916, 904.927/928 with code H93 or code H94 with code M55 with compressor 393 cm3 displacement)

8

A 002 997 58 90

Cable tie (355 mm to 375 mm, attachment of fuel line with protective hose to hydraulic line) (only with engine 900.915/916, 904.927/928 with code H93 or code H94 with code M55 with compressor 393 cm3 displacement)

4

A 015 997 48 45

O-ring (power steering pump)

1

A 904 134 00 07

Resonator (only with engine 902, 906)

1

A 906 130 66 15

Compressor

1

A 906 203 73 02

Coolant line (only with engine 904.927/928, 906.935/955 with compressor 238 cm3 or compressor with optimized cylinder head (A 001 130 79 15))

1

A 405 528 21 82

Air intake hose (only with ENGINE 902, 906 in MODEL 405 up to vehicle identification end number 218033)

1

N 000000 000667

Clamp (only for ENGINE 902, 906 with resonator)

2

N 000000 001069

Sealing ring (coolant line on compressor)

4

N 005401 309000

Ball (only with engine 900.915/916/920/921, 902.923/924, 924.923/931 with compressor 352 cm3 displacement)

1

N 007603 026404

Sealing ring (threaded fitting on cylinder head)

1

N 910142 010006

Screw/bolt M10x25, 10.9

1

N 915017 006100

Union nut (only with engine 900.915/916/920/921, 902.923/924. 924.923/931 with compressor 352 cm3 displacement)

1