Attach/detach test adapter to XENTRY for guided measurement for return quantity of pressure limiting valve

AR07.16-W-0160H

Attach/detach test adapter to XENTRY for guided measurement for return quantity of pressure limiting valve

10.04.2019

Engine

471.9## ## up to 032690 in model 963, 964

Modification notes

13.03.2013

Remove, install resonator (1), added.

Operation steps 4, 21

AR13.10-W-5840HA

Shown with front expansion reservoir

1

Resonator

3

Compressor air intake duct

5

Fuel line (nozzle needle valve return line)

2

Compressor air intake duct

4

Bracket

6

Fuel line (pressure limiting valve return line)

5

Fuel line (nozzle needle valve return line)

6

Fuel line (pressure limiting valve return line)

7.1

Plug

7.2

Test adapter

 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

 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 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 it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A

Installing

1

Tilt cab

2

Remove soundproofing

3

Clean engine in the area of fuel filter module and fuel lines (5, 6)

4

Remove resonator (1)

AR13.10-W-5840HA

5

Disconnect air intake duct for compressor (3) from compressor

6

Remove bracket (4)

7

Detach fuel line (5) from threaded fitting of cylinder head and fuel filter module


When detaching the fuel line (5) counterhold the threaded fitting on the cylinder head using the  counterholder.
Otherwise the fuel line (5) may be damaged.

 Collect escaping fuel.

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

 Counterholder

*470589000100

8

Remove fuel line (6) from fuel filter module and rail

 Collect escaping fuel.

 Box wrench socket

*314589010300

9

Fit stop plug (7.1) to fuel filter module

 Stop plug to fuel filter module

*BA07.16-N-1036-03A

 Box wrench socket

*314589010300

 Test adapter

*470589022100

10

Connect test adapter (7.2) to rail

 Banjo bolt, test adapter to rail

*BA07.16-N-1039-03A

 Test adapter

*470589022100

11

Connect test adapter (7.2) to measuring tank

 Test adapter

*470589022100

12

Fit fuel line (5) to threaded fitting of cylinder head and fuel filter module

 Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

*BA07.16-N-1019-03A

 Union nut, fuel line (nozzle needle valves return) to fuel filter module pressure regulating valve

*BA07.16-N-1020-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

Remove

13

Detach fuel line (5) from threaded fitting of cylinder head and fuel filter module

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

 Counterholder

*470589000100

14

Remove test adapter (7.2) from measuring tank

15

Remove test adapter (7.2) on rail

16

Remove stop plug (7.1) from fuel filter module

 Box wrench socket

*314589010300

17

Attach fuel line (6) to fuel filter module and to rail

 Replace sealing rings on rail.

 Union nut, fuel line from rail (pressure limiting valve return) to fuel filter module

*BA07.16-N-1023-03A

 Banjo bolt, fuel line to rail (pressure limiting valve return)

*BA07.16-N-1024-03A

 Box wrench socket

*314589010300

18

Fit fuel line (5) to threaded fitting of cylinder head and fuel filter module

 Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

*BA07.16-N-1019-03A

 Union nut, fuel line (nozzle needle valves return) to fuel filter module pressure regulating valve

*BA07.16-N-1020-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

19

Replace bracket (4) and high-pressure lines to rail

AR07.16-W-1004H

 The bracket (4) and the high-pressure line to the rail must not be reused. They must be replaced together with the clamps and the vibration dampers.

20

Attach air intake duct for compressor (3) to compressor

21

Install resonator (1)

AR13.10-W-5840HA

22

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

If engine fails to start or only runs for a brief period:



Fill low-pressure fuel circuit.

AR07.16-W-1007H

23

Check area of fuel filter module and fuel lines (5, 6) for leaktightness, and switch off engine

 Visual inspection.

24

Attach soundproofing

25

Tilt back cab

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1019-03A

Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

M16x1.5

Nm

25

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1020-03A

Union nut, fuel line (nozzle needle valves return) to fuel filter module pressure regulating valve

M16x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1023-03A

Union nut, fuel line from rail (pressure limiting valve return) to fuel filter module

M16x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1024-03A

Banjo bolt, fuel line to rail (pressure limiting valve return)

M14x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1036-03A

Stop plug to fuel filter module

M16x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1039-03A

Banjo bolt, test adapter to rail

M14x1.5

Nm

30