W01.10-1028-09
Shown on model 944 |
1 | Engine wiring harness | 8 | Air intake hose | 16 | Electrical line | ||
1.1 | Electrical line (red) | 9 | Vent line | 17 | Running board | ||
2 | Cab-chassis connector plate | 10 | Coolant hose | 18 | Rear cab carrier | ||
3 | Coolant expansion reservoir | 11 | Coolant hose | 19 | Compressed air lines | ||
4 | Radiator | 12 | Air intake pipe | B17 | Speed sensor | ||
5 | Coolant level switch electrical line | 13 | Air intake line (compressor) | X2.1 | Cab-chassis connector | ||
6 | Coolant hose | 14 | Propeller shaft | X2.2 | Cab-chassis connector | ||
7 | Charge air hose | 15 | Compressor-air line compressor | X2.3 | Cab-chassis connector |
W01.10-1029-09
15 | Compressor-air line compressor | 28 | Compressed-air line constant throttle | 34 | Filler pipe fitting | ||
23 | Load tilter | 29 | Power steering pump | 35 | Poly-V-belt (only for vehicles with code H03 (Air conditioning system in front-end assembly)) | ||
24 | Chain hoist | 30 | Hand pump | 36 | Oil hose (only for code N55 (transmission oil cooling) | ||
25 | Exhaust flex pipe | 31 | Fuel feed line | 37 | Coolant hose | ||
26 | Compressor control compressed-air line | 32 | Return fuel line | 38 | Refrigerant compressor (only for vehicles with code H03 (Air conditioning system in front-end assembly)) | ||
27 | Compressed-air line engine brake | 33 | Fuel filter | 39 | Filler pipe |
Shown on vehicles with code GS1 ("mechanical" gearshift) |
25 | Exhaust flex pipe |
42 | Telescopic rod (only for code GS1 ("mechanical" gearshift)) |
43 | Relay lever (only for code GS1 ("mechanical" gearshift)) |
44 | Support rod gate (only for code GS1 ("mechanical" gearshift)) |
46 | Exhaust pipe |
W01.10-1030-11
Only for transmission 715.510/520/561 with code GS3 ("hydraulic" gearshift) |
47 | Hydraulic lines |
47.1 | O-ring |
48 | Hydraulic lines |
49 | Retaining clamp |
W26.60-1190-11
50 | Clutch booster |
51 | Electrical connector |
52 | Hydraulic line |
53 | Banjo union with line |
54 | Compressed-air line |
55 | Banjo bolt |
W25.20-1040-11
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. | |
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. | |
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. | |
Warning | Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid. | Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. | |
Warning | Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue | Pour AdBlue into suitable containers only. Wait until the pressure is released before starting any work on the exhaust aftertreatment system. | |
Warning | Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant. | Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. | |
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. | |
Topical note | Notes on self-locking nuts and bolts | ||
Topical note | Notes on coolant | ||
Topical note | Notes on tilting the cab | ||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
Notes on hydraulic fluid as per specification Sheet 345.0 | |||
Notes on use, material properties and handling of AdBlue® | |||
Notes on engine oil | |||
| Remove/install | ||
1 | Switch off ignition | ||
2 | Put the gearshift lever in neutral position | Only for vehicles with code GS3 ("hydraulic" gearshift) | |
Less hydraulic fluid will then run out when hydraulic lines (47, 48) are disconnected. | |||
3 | Open cap on fuel tank | ||
4 | Disconnect battery ground line | ||
5 | Open maintenance flap | ||
6 | Remove trim element | ||
7 | Remove cover of cab-chassis connector plate (2). | Installation: Check seal in the cover for damage. | |
If seal in the cover is damaged. | |||
| |||
Replace cover. | |||
8 | Detach electrical line (red) (1.1) and cab-chassis connectors (X2.1, X2.2, X2.3) from cab-chassis connector plate (2) | ||
9 | Unclip engine wiring harness (1) and place in bottom | ||
10 | Tilt cab | ||
11 | Remove noise encapsulation on frame at top left, right and bottom | ||
12 | Close off hose and line connections on exhaust aftertreatment system | Only for vehicles with code MS4 (BlueTec 4 (Euro IV)) or code MS5 (BlueTec 5) | |
Clamp | |||
13 | Drain off coolant | ||
14 | Remove engine wiring harness (1) from bracket and frame and tie to engine | ||
15 | Disconnect electrical line of coolant level switch (5) from the coolant level switch, unclip from coolant expansion reservoir (3) and coolant hose (6) | Tie electrical line for coolant level switch (5) to engine. | |
16 | Pull out retaining clamps (49), disconnect hydraulic lines (47, 48) from the connector couplings and remove O-rings (47.1) | Only for vehicles with code GS3 ("hydraulic" gearshift) | |
Collect hydraulic fluid and plug hydraulic lines (47, 48) with suitable stop plugs. | |||
Plug | |||
17 | Remove charge air pipe of charge air cooler from charge air distributor | ||
18 | Remove charge air hoses (7) | | |
Installation: Check charge air hoses (7) and clamps for their condition. | |||
Clamp, charge air hose to charge air housing/charge air pipe and charge air cooler | |||
If the charge air hoses (7) or clamps are damaged. | |||
| |||
Replace charge air hoses (7) or clamps. | |||
19 | Remove top coolant hoses (6, 10, 11) from the cooler (4) or from the coolant expansion reservoir (3) | Collect escaping coolant in a clean vessel. | |
20 | Disconnect bleed line (9) from air intake hose (8) and remove air intake hose (8) | ||
21 | Remove compressor air intake line (13) from air intake pipe (12) | Installation: Check sealing ring on compressor air intake line (13) for damages. | |
If sealing ring on compressor air intake line (13) is damaged. | |||
| |||
Replace sealing ring on compressor air intake line (13). | |||
22 | Remove telescopic rod (42) on relay lever (43) and gate support rod (44) | Only for vehicles with code GS1 ("mechanical" gearshift) | |
Ball head for telescopic shift rod to relay lever | |||
Ball head for selector rod on gate | |||
23 | Connect telescopic rod together (42), swivel upwards and tie to cab | Only for vehicles with code GS1 ("mechanical" gearshift) | |
24 | Disconnect compressor control compressed-air line (26), constant throttle compressed-air line (28), and engine brake compressed-air line (27) at connections | ||
25 | Disconnect and remove exhaust pipe (46) from exhaust flex pipe (25) and from rear muffler | Installation: Check exhaust flex pipe (25) for damages. | |
Bolt, clamp to premuffler, exhaust pipe, rear muffler and flexible exhaust pipe | |||
Bolt, clamp to bracket | |||
If exhaust flex pipe (25) is damaged. | |||
| |||
Replace exhaust flex pipe (25). | |||
26 | Remove running board (17) above transmission | If present. | |
27 | Remove compressed-air lines (19) from rear cab carrier (18) | ||
28 | Remove rear cab carrier (18) from the frame | Disconnect all cable ties and put rear cab carrier (18) with attached lines to the side. | |
Bolt, rear cab support to vehicle frame | |||
29 | Only disconnect propeller shaft (14) from transmission output flange | ||
Support propeller shaft (14). | |||
30 | Disconnect electrical line (16) from speed sensor (B17) | ||
31 | Remove compressed-air line of compressor (15) from brackets and from connections in the frame and check for carbonization | If compressed-air line of compressor (15) is carbonized. | |
| |||
Replace compressed-air line of compressor (15). In addition, check compressed-air lines between compressor, compressed-air dryer and four-circuit protection valve. | |||
If compressed-air lines between compressor, compressed-air dryer and four-circuit protection valve are carbonized. | |||
| |||
Replace respective compressed-air line. | |||
32 | Remove power-steering pump (29) from compressor and tie to frame | Do not disconnect steering gear oil lines. | |
Bolt, power steering pump to compressor | |||
33 | Remove cross-staff head from power-steering pump (29) or from compressor | Installation: Insert cross-staff head in compressor and secure against slipping with high-temperature grease. | |
High-temperature grease | |||
34 | Release and disconnect fuel feed line (31) from hand pump (30) and remove from bracket | Collect escaping fuel. | |
35 | Release and disconnect return fuel line (32) from fuel filter (33) and remove from bracket | Collect escaping fuel. | |
36 | Remove coolant hose (37) from cooler (4) | Collect escaping coolant in a clean vessel. | |
37 | Disconnect oil lines of oil cooling at the connections of transmission oil hoses (36) | Only for vehicles with code N55 (transmission cooling) | |
Collect escaping transmission oil and plug openings with stop plugs. | |||
Plug | |||
38 | Remove filler pipe (39) from filler pipe fitting (34) | Plug filler pipe fitting (34). | |
Installation: Check sealing ring on filler pipe (39) for damages. | |||
If sealing ring on filler pipe (39) is damaged. | |||
| |||
Replace sealing ring on filler pipe (39). | |||
39 | Release poly-V-belt (35) and remove from belt pulley of refrigerant compressor (38) | Only for vehicles with code H03 (air conditioning system in front-end assembly) | |
Routing diagram for poly-V belt | |||
| Damage profiles for a poly-V belt | ||
Installation: Check poly-V-belt (35) for condition. | |||
If poly-V-belt (35) is damaged. | |||
| |||
Replace poly-V-belt (35). | |||
40 | Disconnect electrical connector from refrigerant compressor (38) | Only for vehicles with code H03 (air conditioning system in front-end assembly) | |
41 | Remove refrigerant compressor (38) from carrier and tie to frame | Only for vehicles with code H03 (air conditioning system in front-end assembly) | |
Do not separate refrigerant lines. | |||
Screw/bolt, A/C compressor to carrier | |||
42 | Disconnect battery line from starter and remove from timing case | Nut, circuit 30 line to starter/solenoid switch | |
43 | Disconnect ground cable from timing case | ||
44 | Disconnect electrical connector (51) from clutch booster (50) | ||
45 | Remove clamp for compressed-air line (54) on transmission | ||
46 | Disconnect compressed-air line (54) from clutch booster (50) | Counterhold banjo bolt (55). | |
Union nut (compressed air line) to clutch actuator/clutch booster | |||
47 | Undo banjo bolt (55) and remove banjo union with line (53) from clutch booster (50) | Banjo bolt (compressed air line) to clutch actuator/clutch booster | |
48 | Remove clutch booster (50) from transmission and tie it to frame | Do not disconnect hydraulic line (52) on clutch booster (50). | |
Bolt, clutch booster to transmission | |||
49 | Remove screws on the right and left engine mounts | Screw/bolt, engine support to engine mount | |
50 | Remove transmission carrier screws on the right and left transmission mounts | Transmission 710.5Bolt, supporting arm to transmission mount | |
Transmission 715.5Supporting arm to frame | |||
Transmission 715.3Supporting arm to frame | |||
51 | Remove engine together with transmission and load tilter | ||
52 | Check engine and transmission mounts for wear | If engine and transmission mounts are worn. | |
| |||
Replace engine and transmission mounts. | |||
Remove/install front engine mount | |||
Remove/install rear engine mount | |||
53 | Install in the reverse order | ||
54 | Teach in all transponder keys (also replacement keys) again | Only when installing a reconditioned engine or a new engine control unit (MR). | |
MODEL 374, 375, 944 | |||
Model 958 | |||
55 | Bleed hydraulic-pneumatic power shift (HPS) | Only for vehicles with code GS3 ("hydraulic" gearshift) | |
56 | Check engine oil level with oil dipstick or on display, add oil if necessary | Observe engine oil quality set in maintenance system or Specifications for Operating Fluids. | |
57 | Check/correct transmission oil level |
| |
Transmission 715 | |||
58 | Start engine and allow to run in idle; oil pressure must have built up after approx. 10 s; then run the engine at varying rpms | The fuel system is bled automatically. | |
If engine fails to start or only runs for a brief period. | |||
| |||
Bleed fuel system manually. | |||
59 | Switch off engine and check for leaktightness | Visual inspection. | |
60 | Synchronize time on tachograph between tachograph disk and display | ||
61 | Update Vehicle Documentation (VeDoc) | Only if a remanufactured engine is installed. | |
Enter engine number in screen 1111. |
963 589 01 91 00
Plug
000 589 54 37 00
Clamp
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