Check compressor for oil ejection

AR13.30-W-0005A

Check compressor for oil ejection

03.11.2015

Engine

541.9 in model 930, 932, 933, 934

with code MZ7 (Air compressor, 1-cylinder, regulated)

Engine

541.9 in model 930, 932, 933, 934

with code MZ8 (Air compressor, 2-cylinder, regulated)

Engine

542.9 in model 930, 932, 934

with code MZ7 (Air compressor, 1-cylinder, regulated)

Engine

542.9 in model 930, 932, 934

with code MZ8 (Air compressor, 2-cylinder, regulated)

Shown on engine 541.9 with a 2-cylinder air compressor

1

Air compressor (upright air compressor)

2.2

Check-compressed air hose

6

Pressure gauge

2

Fitting (working connection)

3

Oil ejection test equipment (adapter)

7

Test kit

2.1

Compressed-air line

5

Measuring hose

11

Test sheet

Shown on engine 541.9 with a 2-cylinder air compressor

0.1

Resonator

4.1

Control line (air compressor recumbent)

4.2

Control line (air compressor upright)

3

Oil ejection test equipment (adapter)

8

Cable tie

9

Adjustment lever

10

Compressed air outlet

11

Test sheet

Oil ejection normal - the diagnostic findings are visibly black but perceptibly dry

A

60 mm

Oil ejection too high - the diagnostic findings are visibly black but perceptibly wet

A

60 mm

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Danger !

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

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

AS60.80-Z-0001-01A

 Danger !

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



Notes on tilting the cab

AH60.80-N-0003-01A



Remove

1

Start engine and bring to normal operating temperature then switch off engine

 Coolant temperature approx. 70 to 95°C.

2

Switch on ignition

3

Tilt cab

4

Remove soundproofing

5

Remove air intake duct with resonator (0.1) on air compressor (1)

 This ensures that the air compressor (1) suctions only oil-free air.

6.1

Remove control line (4.1) on air compressor (1)

Vehicles with code MZ7(Air compressor, 1 cylinder, regulated)

 By taking this measure one can ensure that the air compressor (1) is also in the delivery phase if the output of the air compressor (1) is impaired by another defect, for example one on the pressure regulator.

6.2

Remove control lines (4.1, 4.2) at air compressor (1)

Vehicles with code MZ8(Air compressor, 2 cylinder, regulated)

 By taking this measure one can ensure that the air compressor (1) is also in the delivery phase if the output of the air compressor (1) is impaired by another defect, for example one on the pressure regulator.

7

Remove air line (2.1) on fitting (2)

8

Prepare test sheet (11) for the oil ejection check on the air compressor (1)



Test sheet for the oil expulsion test at the compressor

WF58.50-W-1330-03A

9

Attach test compressed air hose (2.2) for the oil ejection test equipment (3) to fitting (2) on the air compressor (1)

 Adapter

*000589039000

10

Fasten the oil ejection test equipment (3) using a cable tie (8) to a suitably stable point on the vehicle

11

Attach test kit (7) with a measuring hose (5) to oil ejection test equipment (3)

 Test kit

*360589002100

12

Fully open the compressed air outlet (10) of the oil ejection test equipment (3) by turning the adjustment lever (9)


Always ensure that the compressed air outlet (10) is fully opened before starting the engine so that the back pressure is at a minimum.
The oil ejection test equipment (3) will be damaged otherwise.

13

Start engine and increase the rpm from idle speed to the maximum governed rpm with the engine start and engine stop button, added



Check

14

Close adjustment lever (9) until the set required back pressure is readable on the pressure gauge (6)


The oil ejection check must always take place with the required back pressure.
A false result will result otherwise.

Oil ejection test (with oil ejection test equipment and test kit)

*BE13.30-N-1018-01B

15

Check air compressor (1) with the prepared test sheet (11) for oil ejection


Ensure that no foreign objects are sucked in via the intake connection during the test run.
Consequential damage can occur at the air compressor (1) otherwise.

 While the engine runs with maximum governed rpm, hold the test sheet (11) at a 10 cm distance in front of the compressed air output (10).

Oil ejection test (with oil ejection test equipment and test kit)

*BE13.30-N-1018-01B

16

Turn off engine

17

Compare the test sheet (11) with the diagnostic findings for oil ejection to assess the oil ejection

If the oil ejection is too high:



Replace air compressor (1).

Vehicles with a 1-cylinder air compressor

AR13.30-W-6010G

Vehicles with a 2-cylinder air compressor (air compressor upright)

AR13.30-W-6010GA

Vehicles with a 2-cylinder air compressor (air compressor recumbent)

AR13.30-W-6010GB

18

Remove oil ejection test equipment (3) and test kit (7) at air compressor (1)

19

Check compressed-air line (operating line) for carbonization

 In the event of carbonization, also check compressed air lines between air compressor (1), compressed air drier and the four-circuit protection valve or the EAPU; replace the carbonized parts if necessary.



Install

20

Attach air line (2.1) to fitting (2)

 Union nut, air line to fitting

*BA13.30-N-1016-01B

21.1

Attach control line (4.1) from air compressor (1)

Vehicles with code MZ7(Air compressor, 1 cylinder, regulated)

21.2

Attach control lines (4.1, 4.2) to air compressor (1)

Vehicles with code MZ8 (Air compressor, 2 cylinder, regulated)

22

Remove air intake duct with resonator (0.1) on air compressor (1)

23

Start engine and run at idling speed

24

Check line interfaces on the air compressor (1) for leaktightness

 Visual inspection.

25

Turn off engine

26

Install soundproofing

27

Tilt back cab

28

Print out questionnaire and fill out completely

Only if the air compressor (1) was replaced and if the cost acceptance was applied for as part of the warranty and goodwill.



Questionnaire for checking delivery rate and oil ejection of air compressor, form

OF13.30-W-1000-02A

 For a warranty or goodwill claim the removed air compressor (1) must be submitted for inspection together with the completely filled out questionnaire and the test sheet used when testing for oil ejection.

Air compressor check values

Number

Designation

ENGINE 541.9, 542.9 with CODE MZ7

ENGINE 541.9, 542.9 with CODE MZ8

BE13.30-N-1018-01B

Oil ejection test (with oil ejection test equipment and test kit)

Back pressure to be set

bar

5

5

Test duration

min

1

1

 Compressor (compressed air system)

Number

Designation

ENGINE 541.9, 542.9

BA13.30-N-1016-01B

Union nut, air line to fitting

M221.5

Nm

65

M261.5

Nm

75