Remove MR/PLD unit pump, install

AR07.15-W-8950J

Remove MR/PLD unit pump, install

23.11.10



Removing

 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

1

Switch off ignition

 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

2

Tilt cab



Notes on tilting the cab

AH60.80-N-0003-01A

3

Remove soundproofing on frame at upper left

4

Remove engine panel (1)

5

Clean crankcase in the area of the relevant unit pump

6

Remove injection line (4) for the corresponding unit pump

AR07.15-W-9235J

7

Mark unit pumps relative to respective cylinder

 Only when removing several unit pumps

8

Remove holder for gearshift lever on cylinder head

 Only on vehicles with code (GS1) "Mechanical" gearshift and for removal of cylinder 1 unit pump (Y6).

9

Remove holder (2) for hydraulic lines and holder (3)

 Only on vehicles with code (GS3) "Hydraulic" gearshift and for removal of cylinder 1 unit pump (Y6).

Do not separate hydraulic lines.

10

Remove mounting strip for electrical engine wiring harness (5) with engine start and engine stop buttons at crankcase

 Only if for engine 900.9, 924.9
the cylinder 2 unit pump (Y7) or cylinder 3 unit pump (Y8) is removed or
for engine 902.9, 925.9, 926.9 the cylinder 4 unit pump (Y9) or cylinder 5 unit pump (Y10) is removed.

11

Disconnect electrical engine wiring harness (5) on the corresponding unit pump

12

Loosen bolts (6) of respective unit pump and undo by around 4 to 5 mm

 The unit pump is under spring force and can suddenly spring out of the crankcase if the bolts (6) are unscrewed completely and get damaged.

13

Install impact extractor (8) on relevant unit pump

 Impact extractor

*355589016300

14

Pull out relevant unit pump using the impact extractor (8) up to the heads of the bolts (6)

 A firmly attached unit pump must not be pushed out at solenoid valve and housing flange, otherwise solenoid valve damage could occur.

15

Remove impact extractor (8)

16

Remove bolts (6) and take out relevant unit pump

17

Check roller tappet (7) at respective unit pump

 Inspect surface of the roller tappet; if there are only minimal scores or scratches, the MR/PLD unit pump (7) can still be used. If deep scoring, scratches or sanding spots are present:



Replace relevant unit pump and also check unit pump lobes on the camshaft by visual inspection.



Install

18

Carefully remove dirt and paint residues on the crankcase sealing surface

 Seal off hole in crankcase.

19

Insert new O-rings on unit pump with lubricant

 Only when reinstalling used unit pumps.

AR07.15-W-8950-01J

 Sleeve

*904589031400

High-temperature grease

*BR00.45-Z-1051-06A

20

Slightly coat unit pump body and the hole in the crankcase with lubricant

High-temperature grease

*BR00.45-Z-1051-06A

21

Insert unit pump in cylinder crankcase and tighten evenly

 Do not damage O-rings at unit pump body.

Press unit pump carefully by hand against the spring force and screw in the bolts (6) at the same time



*BA07.15-N-1001-01A

22

Fit mounting strip for electrical engine wiring harness (5) with engine start and engine stop buttons at crankcase

 Only if for engine 900.9, 924.9
the cylinder 2 unit pump (Y7) or cylinder 3 unit pump (Y8) is installed or
for engine 902.9, 925.9, 926.9 the cylinder 4 unit pump (Y9) or cylinder 5 unit pump (Y10) is installed.

23

Connect electrical wiring harness (5) at respective unit pump

24

Attach holder for gearshift lever on cylinder head

 Only on vehicles with code (GS1) "Mechanical" gearshift and after installation of cylinder 1 unit pump (Y6).

25

Install holder (3) and holder (2) for hydraulic lines

 Only on vehicles with code (GS3) "Hydraulic" gearshift and after installation of cylinder 1 unit pump (Y6).

26

Install injection line (4) for the corresponding unit pump

AR07.15-W-9235J

 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

27

Conduct engine test run, stop engine and check in area of unit pumps for leaks

 Crank engine with the starter for not more than 90 seconds. The fuel system is bled automatically. If the engine stops or does not start, repeat starting procedure after a break of 2 minutes.

28

Connect STAR DIAGNOSIS and teach in bar code of unit pump

 Only when installing new unit pumps.

29

Install engine panel (1)

30

Install soundproofing on frame above on the left

 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

31

Lower cab



Notes on tilting the cab

AH60.80-N-0003-01A

Number

Designation

Engine
900.9,

Engine
902.9
without code MS8

Engine
924.9, 925.9, 926.9

BA07.15-N-1001-01A

Bolt, unit pump to crankcase

Nm

65

65

Number

Designation

Order number

BR00.45-Z-1051-06A

High-temperature grease

A 000 989 81 51