Inspect cylinders with a light probe

AR01.00-W-0200O

Inspect cylinders with a light probe

20.11.2017

Engine

460.9 in model 963, 964

Shown on cylinder 4

1

Endoscope

2

Inspection light

3

Protective sleeve

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01B

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

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

 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 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes and information on working on complete engine, crankcase ventilation system, cylinder head, cylinder crankcase

AH01.00-N-0002-01B



Remove

1

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

 Coolant temperature approx. 80 °C.

2

Tilt cab

3

Remove soundproofing on frame at the left

4

Remove soundproofing below the engine

5

Attach turning device for engine

AR03.30-W-1600-05O

 Bolt, turning device to timing case

*BA01.60-N-1002-01OA

 Turning device

*904589046300

6

Remove charge-air distributor

AR09.41-W-8683O

7

Remove cylinder head cover on the cylinder to be checked

AR01.20-W-5014O

8

Remove injection line on the cylinder to be checked

AR07.15-W-8971O


The injection line must not be bent.
Otherwise the coating comes off in the injection line and engine damage occurs.

9

Remove nozzle holder combination of cylinder to be checked

AR07.03-W-6831O

 The sealing sleeve of the nozzle holder combination must be removed.

Illuminate

10

Attach endoscope (1) to inspection light (2) and switch on

 Observe manufacturer's operating instructions.
Use commercially available endoscope (1) with a diameter of  8.9  mm.

11

Insert endoscope (1) through bore of the protective sleeve (3) of the cylinder to be tested


The endoscope (1) must not touch on or hit against the piston crown.
Otherwise, the tip of the endoscope will be damaged.

 The ambient temperature must be  80 °C.

12

Carefully position piston on cylinder to be tested at bottom dead center


The endoscope (1) must not touch on or hit against the piston crown.
Otherwise, the tip of the endoscope will be damaged.

 Check position of the piston through the endoscope (1) and turn the crankshaft correspondingly with the  turning device.

 Turning device

*904589046300

13

Check the cylinder barrel, piston crown, clearance volume, and valves for damage

In case of damage or when in doubt.



Remove corresponding cylinder head.

AR01.30-W-5800O

14

Pull the endoscope (1) out of the bore of the protective sleeve (3)

15

Check remaining cylinders in the same way

If required.

 To do this, repeat operation steps 7 to 13 accordingly.
If necessary check cylinders in pairs in 3 crankshaft positions.
Cylinders 1 and 6
Cylinders 2 and 5
Cylinders 3 and 4



Install

16

Install nozzle holder combination

AR07.03-W-6831O

17

Install injection line

AR07.15-W-8971O


The injection line must not be bent.
Otherwise the coating comes off in the injection line and engine damage occurs.

18

Install cylinder head cover

AR01.20-W-5014O

19

Install charge air distributor

AR09.41-W-8683O

20

Remove turning device for the engine and attach cap

AR03.30-W-1600-05O

 Bolt, inspection hole cap to timing case

*BA01.60-N-1001-01OA

21

Install soundproofing below the engine

22

Install soundproofing on frame at the left

23

Tilt back cab

 Timing case

Number

Designation

Engine 460.9 in model 963, 964

BA01.60-N-1001-01OA

Bolt, inspection hole cap to timing case

Nm

25

 Timing case

Number

Designation

Engine 460.9 in model 963, 964

BA01.60-N-1002-01OA

Bolt, turning device to timing case

Nm

25