Remove/install engine

AR01.10-W-2400F

Remove/install engine

14.2.12

21.3.07

Gear hydraulic cylinder to transmission housingM16

Transmission 712.63, 715.060 with code GS3

*BA26.60-N-1024-01D

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground lead from battery



Notes on battery

AH54.10-P-0001-01A

2

Disconnect engine wiring harness at plug connection of cab-chassis

AR01.00-W-2410F

3

Remove radiator

AR20.20-W-3865F

4

Remove soundproofing on the left and right on the frame and soundproofing below

5

Detach hydraulic pump or propeller shaft at engine power take-off and paneling above transmission

 Only for code (N52) rear engine power take-off, output torque 600 Nm,

Code (NJ7) Rear power take-off for hydraulic pump, max. 120 Nm or

Code (NJ9) Rear power take-off for hydraulic pump, max. 200 Nm.

6.1

Remove gearshift lever with gearshift linkage (30) on bracket (31)

With code (GS1) "Mechanical" gearshift.

6.2

Detach hydraulic lines from engine and transmission as well as hydraulic gear and gate shift cylinders at transmission

With code (GS3) "Hydraulic" gearshift.
 Do not disconnect hydraulic lines. Lay shift cylinder to one side with hydraulic lines connected.

Without code (IY2) Hydraulic fluid as per sheet 345.0

AR26.60-W-7000-01A

With code (IY2) Hydraulic fluid as per sheet 345.0

AR26.60-W-7000-01B

 Gear hydraulic cylinder to shift shaft

*BA26.60-N-1009-01D

 Bearing bracket to transmission housing

*BA26.60-N-1010-01D

 Gate hydraulic cylinder to transmission housing

*BA26.60-N-1011-01D

 Gate hydraulic cylinder to shift shaft

*BA26.60-N-1012-01D

 Gear hydraulic cylinder to transmission housing
 Not for transmission 715.5

*BA26.60-N-1024-01D

 Compressed air line to gear control valve/ shift cylinder

*BA26.60-N-1005-01F

 Gear hydraulic shift cylinder to
Gear module
 Only for code (IY2) Hydraulic fluid as per sheet 345.0

*BA26.60-N-1047-01D

7

Remove air intake hose (14) with crankcase ventilation hose (13)

8

Remove exhaust pipe (4) at engine brake flap connection and at rear lifting eye

 Installation: Check clamp for wear and tear, replace if necessary.

9

Disconnect electrical wiring harness (3) at bracket (1) in right frame longitudinal

10

Detach compressed air line (15) from engine brake cylinder

11

Disconnect transmission connectors (X29) for transmission wiring harness and remove at bracket

12

Remove terminal 30 (16) line at starter



*BA15.30-N-1002-01B

13

Slacken poly-V belt and remove

 Only with code (H03) Air conditioning in front end.

AR13.22-W-1202A

14

Disconnect electrical connector for refrigerant compressor (11) and remove refrigerant compressor (11) with bracket at engine then bind up to the side

 Only with code (H03) Air conditioning in front end.

Do not separate refrigerant lines.



*BA01.40-N-1005-01C

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

15

Open cap on fuel tank and disconnect fuel feed and return lines (9) at fuel filter

 Collect escaping fuel. Mark fuel feed and return lines (9) and bind up to the side.



*BA47.25-N-1008-01J

16

Remove oil filler pipe (12)

 Seal opening at the oil pan.

17.1

Remove power steering pump and bind up to the side with attached steering pressure and suction line (10)

Not if a reconditioned engine is installed.

 Do not disconnect steering pressure and suction line (10).



*BA46.30-N-1001-01B

Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize hydraulic system completely before starting any work on system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

17.2

Disconnect both hoses on steering pressure and suction line (10)

Only if a reconditioned engine is installed.

 Catch escaping hydraulic fluid. The power steering pump is also supplied when a reconditioned engine is installed.

18

Release and disconnect electrical connectors (7, 8) at the engine control (MR) control unit

 Bind electrical connector (7) to the side and bind electrical connector (8) to the engine.

19

Remove compressed air line (5) at compressor and at brackets on transmission and check compressed air line (5) for carbonization

 In the event of coking, also check compressed air line (5) between compressor, compressed air drier and four circuit protection valve; replace coked parts if required.

20

Detach transmission oil lines (17) at engine

 Only with code (N55) Transmission oil cooling. Collect escaping transmission oil.

21

Remove clutch servo unit (6) at transmission and attach to frame

 Only transmission 715.3/5

Do not separate hydraulic lines.

Disconnect electric cable and compressed air line.

 Installation: Grease plunger head.

*BR00.45-Z-1062-06A

22

Attach transmission or support

23

Unscrew bolts from transmission at engine



*BA26.10-N-1006-01C

24

Unscrew screw/bolts at both engine mounts (2)

 Check engine mount (2) for wear and replace if necessary.

25

Remove engine with removal fixture

 Do not damage electrical connector (8) when lifting out engine.

AR01.10-W-2400-01F

 Installation: In case of clutch plate without a nickle-plated hub surface (surface of the plate), apply a little grease to transmission input shaft.

*BR00.45-Z-1062-06A

First remove engine hoist and chain hoist if engine is attached.

Load regulator

gotis://H_00.12_04.0



Hub surface of drive plate is nickel-plated

Only model 950, 952, 953, 954 with transmission 715.5.

BT25.10-W-0050-01A

26

Install in the reverse order

27

Check engine oil level using oil dipstick or on display, correct if necessary

 Observe engine oil grade set in maintenance system or Specifications for Operating Fluids.

28

Initialize all transponder keys

 Only if reconditioned engine is installed.

AR80.57-W-0010C

29

Pour in transmission oil up to the lower edge of the opening for the inspection plug

 Only with code (N55) Transmission oil cooling.



Gear oils (Sheet 235.01)

Sheet 235.1

BB00.40-P-0235-01A



Synthetic gear oils (SAE 75 W/85 W)

Sheet 235.4

BB00.40-P-0235-04A



Gear oils (SAE 80, 80 W/85 W)

Sheet 235.5

BB00.40-P-0235-05A



Gear oils (sheet 235.11)

Sheet 235.11

BB00.40-P-0235-11A

 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

30

Start engine and observe oil pressure gauge with the engine idling

 Crank engine with the starter for not more than 90 seconds. Wait at least for about 2 minutes before repeating attempt at starting.

Do not rev up engine before oil pressure is indicated. The oil pressure gauge must indicate oil pressure after about 10 seconds.

*BE18.00-N-1001-01C

31

Bleed steering system

 Only if a reconditioned engine is installed.

AR46.25-W-3300C

32

Turn off engine

33

Check engine, compressed air line (5), cooling system and steering hydraulics for leaks

34

Set time and synchronize tachograph

35

Enter engine number in FDOK "Screen 1111"

 Only if a reconditioned engine is installed.

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BE18.00-N-1001-01C

Engine oil pressure at

Idling speed

bar

0.5

maximum speed

bar

2.5

Number

Designation

Engines 900.9, 902.9, 904.9, 906.9

BA01.40-N-1005-01C

Screw/Screw/bolt, refrigerant compressor carrier to crankcase

Nm

55

Number

Designation

Engines
900.9, 902.9, 904.9, 906.9

BA15.30-N-1002-01B

Nut, terminal 30 at starter

Nm

30

Number

Designation

Trans-mission
710.81

Trans-mission 712.63,
715.060/
068

Trans-mission 715.320/
321

Trans-mission 715.500/
507/510/
513/517/
520/527/
540/561/
567/568

Trans-mission 715.570/
576

BA26.10-N-1006-01C

Transmission to engine

Nm

50

50

50

50

50

Number

Designation

Transmission 712.63,
715.060
with code GS3

Transmission
715.320 with code GS3

BA26.60-N-1009-01D

Gear hydraulic cylinder to shift shaft

Nm

60

70

BA26.60-N-1010-01D

Bearing bracket to transmission housing

Nm

-

-

BA26.60-N-1011-01D

Gate hydraulic cylinder to transmission housing

Nm

25

25

BA26.60-N-1012-01D

Gate hydraulic cylinder to shift shaft

Nm

35

-

BA26.60-N-1024-01D

Gear hydraulic cylinder to transmission housing

M10

Nm

60

45

M12

Nm

-

80

M16

Nm

100

-

Number

Designation

Transmission 715.500/507/510/513/520/540
with code GS3 without code IY2

Transmission 715.500/507/510/513/520/540/561 with code GS3 and code IY2

BA26.60-N-1009-01D

Gear hydraulic cylinder on shift shaft

Nm

50

-

BA26.60-N-1010-01D

Bearing bracket on transmission housing

Nm

80

-

BA26.60-N-1011-01D

Gate hydraulic cylinder on transmission housing

Nm

50

25

BA26.60-N-1012-01D

Gate hydraulic cylinder on shift shaft

Nm

50

-

BA26.60-N-1047-01D

Gear hydraulic shift cylinder on gear module

Nm

-

50

Number

Designation

Transmission
715.320/321

BA26.60-N-1005-01F

Pressure line to control valve / gear shift cylinder

M10

Nm

20

M12

Nm

30

Number

Designation

Steering
765.8, 766.4
with engine
900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9

BA46.30-N-1001-01B

Screw/Screw/bolt, power steering pump to compressor

Nm

40

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9

BA47.25-N-1008-01J

Nut, feed and return line to fuel filter

Nm

45

Number

Designation

Order number

BR00.45-Z-1062-06A

Lubricating grease, Olista Longtime, DB supply specification 6804.60

A 001 989 36 51 10