SM20.40-W-0002A | Converting high-speed fan drive with planetary drive to high-speed fan drive with belt drive | 19.12.11 |
ENGINE 541.9 in MODELS 950, 952, 953, 954
with CODE (ML1) High-speed fan drive with planetary gear
except CODE (MN9) Preinstallation for retrofitting FRIGOBLOCK
ENGINE 542.9 in MODELS 950, 952, 954
with CODE (ML1) High-speed fan drive with planetary gear
except CODE (MN9) Preinstallation for retrofitting FRIGOBLOCK
W20.40-1020-09
1 Viscous fan clutch
2 Intermediate piece
3 Planetary-driven high-speed fan drive
4 Screw
5 Coolant pump belt pulley
6 Coolant pump
7 Oil filter housing
8 Refrigerant compressor belt pulley
9 Retaining ring
10 Spacer rings
11 Pressure plate
12 Screw
13 Belt pulley with vibration damper
14 Splash ring
15 Poly-V belt for alternator
16 Tensioner, poly-V belt for alternator
17 Nut
18 Thrust washer
19 Alternator belt pulley
Operation no. of operation texts or standard texts and flat rates
Category | Op. no. | Operation text | Time | Acc. no. | Code |
O | 024142 | OPERATION: CONVERT PLANETARY-DRIVEN HIGH-SPEED FAN DRIVE TO BELT-DRIVEN HIGH-SPEED FAN DRIVE | 097 WU/8.1 h | 20 304 01 | --- |
O | 024143 | OPERATION: ADDITIONAL WORK FOR CONVERTING HIGH-SPEED FAN DRIVE ON VEHICLES WITH AIR CONDITIONING | 003 WU/0.25 h | 20 304 01 | --- |
O | 024144 | OPERATION: ADDITIONAL WORK FOR CONVERTING HIGH-SPEED FAN DRIVE ON VEHICLES WITH OLD OIL FILTER HOUSING | 048 WU/4.0 h | 20 304 01 | --- |
O | 831762 | OPERATION: EVACUATE REFRIGERANT AND CHECK FOR LEAKAGE; REFILL (WHEN WORKING ON SYSTEM); ALL AIR CONDITIONING SYSTEMS | 012 WU/1.0 h | --- | --- |
O | 204320 | OPERATION: ADDITIONAL WORK FOR REMOVING AND INSTALLING RADIATOR ON VEHICLES WITH AIR CONDITIONING | 008 WU/0.7 h | --- | --- |
Modification notes
| Removing | ||
Danger! | Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension | Use only approved tensioning devices; shield off hazard area if necessary. | |
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. | |
1 | Tilt cab | ||
| Notes on tilting the cab | ||
Danger! | Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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. Wear protective gloves, protective clothing and safety glasses. | |
2 | Remove radiator | ||
| Notes on coolant | ||
3 | Remove planetary gear for high-speed fan drive (3) | ||
4 | Loosen nut (17) for pulley (19) from generator | ||
5 | Loosen screw (12) for pressure plate (11) from refrigerant compressor | Only on models fitted with air conditioning. | |
6 | Loosen screws (4) for pulley from coolant pump (6) | ||
7 | Relieve the tension on the poly-V belt for the alternator (15) and then remove poly V-belt from the tensioner pulley on the poly-V belt tensioner (16) | ||
8 | Remove the poly-V-belt belt tensioner for the alternator (16) along with the tensioner pulley | ||
9 | Remove pulley for generator (19) | ||
10 | Remove belt pulley from coolant pump (6) | ||
11 | Remove pressure plate (11) with spacers (10) | Only on models fitted with air conditioning. | |
12 | Remove refrigerant compressor pulley (8) | Only on models fitted with air conditioning. | |
The pulley is secured on the compressor shaft with a retaining ring (9). | |||
13 | Block engine with rotating device | | |
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14 | Remove pulley with vibration damper (13) and splash ring (14) | Installation: Be sure to note the position of the slinger (14). | |
15 | Remove coolant pump (6) | As of engine end no. 109 391, remove the start/stop switch on the bracket, do not disconnect electrical connector. | |
16 | Remove oil filter housing (7) | Up to engine end no. 109 390. | |
As of engine end no. 109 391, the thread for the tensioner pulley for the high-speed fan drive is available in the oil filter housing. | |||
17 | Unscrew intermediate flange (2) from viscous fan clutch (1) | ||
| Install | ||
18 | Install new oil filter housing (7) | Up to engine end no. 109 390. | |
After replacing the oil filter housing, transfer the oil pressure, oil temperature and coolant temperature sensors to new oil filter housing. | |||
After conversion it is necessary to extend the connection cables for the oil pressure and oil temperature sensors. | |||
Threaded bolt on oil filter housing | |||
Oil temperature sensor (B11) | |||
Coolant temperature sensor (B65) | |||
Oil filter cover | |||
Oil/water heat exchanger housing | |||
Cap screws | |||
Oil-water heat exchanger | |||
Oil pressure sensor (B12) | |||
Fuel filter housing | |||
Fuel line mount | |||
19 | Install new coolant pump (6) | Replace gasket for coolant pump. | |
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20 | Install new belt pulley for coolant pump (5) | ||
21 | Install new pulley with vibration damper (13) and splash ring (14) | Observe installation position of the slinger. | |
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22 | Install new pulley for refrigerant compressor (8) | Only on models fitted with air conditioning. | |
The pulley is secured on the compressor shaft with a retaining ring (9). | |||
23 | Install pressure plate (11) with spacers (10) | Only on models fitted with air conditioning. | |
24 | Install new pulley for generator (19) | ||
25 | Install new belt tensioner with tensioner pulley (16) for poly-V belt drive of alternator | ||
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26 | Pivot tensioner pulley upward and install new poly-V belt (15) for alternator | Pay attention to poly-V belt routing plan. | |
27 | Tighten pulley for coolant pump and generator as well as pressure plate for refrigerant compressor | | |
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28 | Install driver and pulley for high-speed fan drive on vibration damper | ||
29 | Install tensioner pulley and poly-V belt for high-speed fan drive | ||
30 | Install fan impeller with viscous fan clutch (1) | Store viscous fan clutch in vertical position for at least one hour before installation. | |
| |||
31 | Remove rotating device and install cap on DTC observation hole | | |
Danger! | Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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. Wear protective gloves, protective clothing and safety glasses. | |
32 | Install radiator | ||
| Notes on coolant | All engines | |
33 | Filling the engine oil circuit | Only when replacing oil filter housing | |
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. | |
34 | Start engine and observe oil pressure gauge with the engine idling | Crank engine with starter for no more than 20 seconds. Repeat starting procedure after a break of approx. 2 min. at the earliest. | |
35.1 | Request engine oil level in display | Model 950, 952, 953, 954 | |
Model 950, 952, 953, 954 | |||
35.2 | Inspect engine oil level with the dipstick | Only if oil level sensor is not parameterized. | |
36 | Switch off engine and check for leaks | Visual inspection. | |
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. | |
37 | Lower cab | ||
| Notes on tilting the cab | Model 950, 952, 953, 954 | |
38 | Document conversion in FDOK | In screen 1512 - on vehicles with retarder enter SA Z 599.020/01 - on vehicles without retarder enter SA Z 599.020/02 | |
In screen 1513 Erase code ML1 and enter code ML3 | |||
In screen 1112 Erase standard engine version. | |||
In screen 1517 Enter following text: | |||
"Conversion to belt-driven high-speed fan drive according to STIN 20.40W005 performed. Please observe when ordering individual parts or replacement engines. Documentation of individual parts in SA Z 599.020. Order RP engines with vehicle ident. no. and note regarding conversion with code ML3" |
Check values for engine oil pressure
Number | Designation | Engine 541.9, 542.9 | ||
BE18.00-N-1001-01D | Engine oil pressure at | Idling speed | bar | 0.5 |
maximum speed | bar | 2.5 | ||
Timing case
Number | Designation | Engine | ||
BA01.60-N-1001-01B | Bolt, end cover of TDC inspection hole to timing case | Nm | 25 | |
BA01.60-N-1009-01B | Bolt, engine cranking device to timing case | Nm | 25 | |
Flywheel, driven plate, vibration damper, starter ring gear
Number | Designation | Engine | ||
BA03.30-N-1002-01F | Bolt, vibration damper to crankshaft | Nm | 200 | |
Charge air pipe/charge air cooling
Number | Designation | Engine | Engine | ||
BA09.41-N-1008-01C | Threaded bolt/bolt on oil filter housing | Nm | 50 | 50 | |
Belt tensioning device
Number | Designation | Engine | ||
BA13.25-N-1001-01D | Bolt of poly V-belt tensioning device to carrier | M10 | Nm | 50 |
M18 | Nm | 105 | ||
BA13.25-N-1003-01D | Bolt, tensioning element to tensioning device | Nm | 35 | |
Alternator
Number | Designation | Engine | Engine | ||
BA15.40-N-1002-01C | Nut, belt pulley to alternator | M161.5 | Nm | 80 | 90 |
Temperature sensor
Number | Designation | Engine 541.9, 542.9 | ||
BA15.60-N-1001-01A | Oil temperature sensor to oil filter housing | M141.5 | Nm | 30 |
BA15.60-N-1002-01A | Coolant temperature sensor to oil filter housing | M141.5 | Nm | 30 |
Oil filter
Number | Designation | Engine | Engine | ||
BA18.20-N-1001-01C | Oil filter cover to oil filter housing | Nm | 40 | 40 | |
BA18.20-N-1002-01C | Bolt, oil filter, oil-water heat exchanger housing to crankcase | Nm | 50 | 50 | |
BA18.20-N-1003-01C | Screw plug on oil filter housing | M141.5 | Nm | 25 | - |
M161.5 | Nm | 25 | - | ||
M241.5 | Nm | 40 | 40 | ||
M332 | Nm | 75 | 75 | ||
Oil cooling system
Number | Designation | Engine 541.9, 542.9 | |
BA18.30-N-1001-01D | Bolt, oil-water heat exchanger to oil filter housing | Nm | 25 |
Oil level/oil pressure sensor
Number | Designation | Engine 541.9, 542.9 | |||
BA18.40-N-1001-01D | Oil pressure sensor to oil filter housing | Nm | 40 | ||
Coolant pump, coolant thermostat
Number | Designation | Engine | ||
BA20.10-N-1001-01D | Bolt, coolant pump to crankcase | Nm | 25 | |
BA20.10-N-1002-01D | Bolt, pulley to coolant pump | Nm | 30 | |
BA20.10-N-1005-01D | Bolt coolant line (inlet connection) to coolant pump | M10 | Nm | 50 |
Fan, fan clutch
Number | Designation | Engine | |
BA20.40-N-1012-01C | Bolt, fan with viscous fan clutch to belt pulley of fan drive | Nm | 50 |
Fuel filter
Number | Designation | Engine 541.9 | Engine 542.9 | |
BA47.20-N-1001-02C | Fuel filter housing to oil filter housing | Nm | 50 | 50 |
Fuel pipes/hoses
Number | Designation | Engine | ||
BA47.25-N-1009-01B | Bolt, bracket of fuel line to oil filter housing | Nm | 25 | |
Refrigerant compressor
Number | Designation | Model | Model | ||
BA83.55-N-1004-01C | Bolt, pressure plate to compressor shaft | Nm | 20 | 20 | |
Cranking device
407 589 00 63 00
Parts ordering notes
Part no. | Designation | Quantity |
A 542 200 08 22 05 | Parts kit for high-speed fan drive with belt drive (vehicles without retarder) | 1 |
A 542 200 07 22 05 | Parts kit for high-speed fan drive with belt drive (vehicles with retarder) | 1 |
A 541 230 05 28 | Clutch disc for refrigerant compressor SA Z 505 159/01 (with unregulated refrigerant compressor) | 1 |
A 541 230 04 28 | Clutch disc for refrigerant compressor SA Z 505 159/04 (with regulated AC compressor) | 1 |
A 541 997 27 92 | Poly-V-belt (with regulated and unregulated refrigerant compressor instead of poly-V belt A 541 997 26 92 from parts kit for high-speed fan drive with belt drive) | 1 |
A 541 188 12 04 | Oil filter housing (up to engine end no. 109 390) | 1 |
A 541 184 06 80 | Gasket for oil filter housing | 1 |