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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training

Global Trainin The finest automotive learning

This document is provided for training purposes only and is not subject to the normal updates.

Printed in Germany

Note: The term «employee» always refers to both male and female staff.

© 2003 Copyright DaimlerChrysler AG Herausgeber: Global Training This documentation and all its constituent parts are subject to copyright. Any reproduction or re use requires written permission from DaimlerChrysler AG in advance. This especially applies to any duplication, dissemination, editing, translation, and microfilming of this documentation, or storage and/or processing on electronic systems, databases and online services. 1511

1209 02

—

1st edition

04.03

236

Content

07.05.2003

Title

Side

Welcome………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 1 Engine model series OM 457 LA…………………………………………………………………………………………………………………………………………………………………………………………………….. 2 Engine OM 457 L A ………………………………………………………………………………………………………………………………………………………………………………………………………………………… 4 Series 457<>Cylinder head…………………………………………………………………………………………………………………………………………………………………………………………………………… 11 Series 457<>Cylinder head — cross section (transverseand longitudinal)………………………………………………………………………………………………………………………………………. 12 Series 457 LA<>Port assignments in the cylinder headgasket……………………………………………………………………………………………………………………………………………………….13 Series 457<>Cylinder head bolts — tightening instructions……………………………………………………………………………………………………………………………………………………………..14 Series 457<>Setting valve p lay……………………………………………………………………………………………………………………………………………………………………………………………………..16 Series 457<>Removing/installing the nozzle holder combination………………………………………………………………………………………………………………………………………………….19 Series 457<>Valve cover and valve cover g a sk e t………………………………………………………………………………………………………………………………………………………………………….25 Series 457<>Oil pan ……………………………………………………………………………………………………………………………………………………………………………………………………………………..26 Series 457<>Pump-line-nozzle injection system ……………………………………………………………………………………………………………………………………………………………………………27 Series 457<>Removing/installing the M R/PLD unit pump…………………………………………………………………………………………………………………………………………………………… 28 Series 457<>Pistons……………………………………………………………………………………………………………………………………………………………………………………………………………………..35 Series 457<>Lubrication schematic diagram……………………………………………………………………………………………………………………………………………………………………………….. 36 Series 457<>Oil spray nozzle……………………………………………………………………………………………………………………………………………………………………………………………………….. 38 Series 457<>Crankcase and cylinder liner…………………………………………………………………………………………………………………………………………………………………………………….39 Series 457<>Cam shaft………………………………………………………………………………………………………………………………………………………………………………………………………………… 40 05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Content

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Series 457<>Fuel system ……………………………………………………………………………………………………………………………………………………………………………………………………………..42 Series 457<>Fuel pump……………………………………………………………………………………………………………………………………………………………………………………………………………….. 45 Series 457<>Fuel prefilter with heated water separator………………………………………………………………………………………………………………………………………………………………. 46 Series 457<>Planetary drive starter…………………………………………………………………………………………………………………………………………………………………………………………….. 48 Series 457<>Fan drive and fan system s………………………………………………………………………………………………………………………………………………………………………………………..50 Series 457<>Air com pressor……………………………………………………………………………………………………………………………………………………………………………………………………….. 52 Series 457<>Turbocharger BR S 4 0 0 ……………………………………………………………………………………………………………………………………………………………………………………………. 53 Series 457<>Engine oil and filter change………………………………………………………………………………………………………………………………………………………………………………………54 Series 457<>Replacing the fuel filter…………………………………………………………………………………………………………………………………………………………………………………………… 56 Series 457<>Fuel filter with water separator — replacing the filter element…………………………………………………………………………………………………………………………………… 58 Series 457<>Air cleaner, engine coolant service …………………………………………………………………………………………………………………………………………………………………………..60 Series 500<>Engine m odels………………………………………………………………………………………………………………………………………………………………………………………………………… 62 Series 500<>Technical features……………………………………………………………………………………………………………………………………………………………………………………………………64 Series 500<>Cylinder head — port assignm ent……………………………………………………………………………………………………………………………………………………………………………… 70 Series 500<>Cylinder head……………………………………………………………………………………………………………………………………………………………………………………………………………71 Series 500<>Cylinder head mounting………………………………………………………………………………………………………………………………………………………………………………………….. 73 Series 500<>Cylinder head gasket………………………………………………………………………………………………………………………………………………………………………………………………..74 Series 500<>EURO 2 and EURO 3 cylinder heads com pared……………………………………………………………………………………………………………………………………………………….. 75 Series 500<>Valve assem bly……………………………………………………………………………………………………………………………………………………………………………………………………….. 77 Series 500<>Pump-line-nozzle injection system (P LD )………………………………………………………………………………………………………………………………………………………………….83 Series 500<>Removing/installing the M R/PLD unit pump…………………………………………………………………………………………………………………………………………………………… 91 Series 500<>EURO 2 and EURO 3 pistons………………………………………………………………………………………………………………………………………………………………………………… 101

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Content

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Series 500<>Connecting rod…………………………………………………………………………………………………………………………………………………………………………………………………….. 102 Series 500<>Crankcase……………………………………………………………………………………………………………………………………………………………………………………………………………. 103 Series 500<>Cylinder liners………………………………………………………………………………………………………………………………………………………………………………………………………. 104 Series 500<>EURO 2 and EURO 3 cylinder liners compared…………………………………………………………………………………………………………………………………………………….. 107 Series 500<>Crankcase ventilation system ……………………………………………………………………………………………………………………………………………………………………………… 108 Series 500<>Fuel system …………………………………………………………………………………………………………………………………………………………………………………………………………. 112 Series 500<>Oil cooler and oil filter housing — component locations………………………………………………………………………………………………………………………………………… 124 Series 500<>Oil circuit…………………………………………………………………………………………………………………………………………………………………………………………………………….. 128 Series 500<>Engine oil system…………………………………………………………………………………………………………………………………………………………………………………………………. 129 Series 500<>Oil spray nozzle…………………………………………………………………………………………………………………………………………………………………………………………………….. 130 Series 500<>Water guide…………………………………………………………………………………………………………………………………………………………………………………………………………. 134 Series 500<>Thermostat location……………………………………………………………………………………………………………………………………………………………………………………………… 136 Series 500<>Supercharging system and charge air ducting……………………………………………………………………………………………………………………………………………………… 137 Series 500<>Engine oil and filter change………………………………………………………………………………………………………………………………………………………………………………….. 140 Series 500<>Cleaning the fuel prefilter / filter insert……………………………………………………………………………………………………………………………………………………………….. 144 Series 500<>-Fuel prefilter with water separator — replacing the filter elem ent…………………………………………………………………………………………………………………………. 146 Series 500<>Replacing the oil separator insert………………………………………………………………………………………………………………………………………………………………………… 148 Series 500<>Replacing the fuel filter — air cleaner — coolant……………………………………………………………………………………………………………………………………………………… 150 Engines OM 904 and 9 0 6 …………………………………………………………………………………………………………………………………………………………………………………………………………. 152 Engine series 9 0 0 …………………………………………………………………………………………………………………………………………………………………………………………………………………….. 153 Series 900<>Technical features……………………………………………………………………………………………………………………………………………………………………………………………….. 156 Series 900<>Port assignments in the cylinder head g a sk e t……………………………………………………………………………………………………………………………………………………… 159

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Series 900<>Tightening instructions for cylinder head bolts…………………………………………………………………………………………………………………………………………………….. 160 Series 900<>Valve control………………………………………………………………………………………………………………………………………………………………………………………………………… 162 Series 900<>Setting valve p lay………………………………………………………………………………………………………………………………………………………………………………………………… 164 Series 900<>Pump-line-nozzle injection system (P LD )……………………………………………………………………………………………………………………………………………………………… 167 Series 900<>Crankcase……………………………………………………………………………………………………………………………………………………………………………………………………………. 185 Series 900<>0lspritzdusen — Unterschiede……………………………………………………………………………………………………………………………………………………………………………….. 188 Series 900<>Pistons and piston rings………………………………………………………………………………………………………………………………………………………………………………………. 189 Series 900<>Connecting rod…………………………………………………………………………………………………………………………………………………………………………………………………….. 190 Series 900<>Pistons and connecting rod — modifications………………………………………………………………………………………………………………………………………………………….. 191 Series 900<>Engine oil circuit………………………………………………………………………………………………………………………………………………………………………………………………….. 192 Series 900<>Removing/installing the oil pan…………………………………………………………………………………………………………………………………………………………………………… 196 Series 900<>Fuel system …………………………………………………………………………………………………………………………………………………………………………………………………………. 200 Series 900<>Supercharging system and charge air ducting……………………………………………………………………………………………………………………………………………………….. 212 Series 900<>Removing/installing the coolant thermostatic control……………………………………………………………………………………………………………………………………………216 Series 900<>Engine oil and filter change…………………………………………………………………………………………………………………………………………………………………………………….218 Series 900<>Cleaning the fuel prefilter — filter insert…………………………………………………………………………………………………………………………………………………………………..221 Series 900<>Fuel prefilter with water separator — replacing the filter elem ent…………………………………………………………………………………………………………………………… 223 Series 900<>Replacing the fuel filter — air cleaner — coolant……………………………………………………………………………………………………………………………………………………….. 226

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07.05.2003

Welcome

OM 457 LA

05/03

OM 502 LA

OM 906 LA

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Welcome

1

07.05.2003

Series 500<>Engine models

The 500 engine model series is future-ready, and comes in V6 and V8 cylinder variants with 2 litre swept volume per cylinder.

odel series 500

The sales designation is formed in the same way as the 400 model series:

6-cylinder engine: OM 501 LA 8-cylinder engine: OM 502 LA

OM 502 LA At the same time, the OM 457 LA engine was developed with the same basic design as the Vengines.

The Series 2000 V12 and V16 MTU engines are derived from the BR 500, and are intended for industrial applications.

OM 501 LA

X.

— Turbocharger Charge air cooler 1=6-cylinder V-engine 2=8-cylinder V-engine Model series 500 Diesel engine

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Engine models

62

N 01.10-2026-11

N01.10-2028-11

The development of the 500 series encapsulates all the knowledge and experience gained from the 1 million V-engines manufactured since 1969, when production of the OM 403 V10 engine began.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Engine models

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07.05.2003

Series 500<>Technical features

^

^

Outstanding power output and torque ch aracteristics over the whole rpm range

^

Dynamic start-off characteristics and pulling power

^

Attractive power/weight ratio

^

Low fuel consum ption

^

Enormous potential: the V6 engines meet the requirements of the highly popular 400 HP Class

^

High-pressure direct injection, pump-line-nozzle system with peak pressures up to 1,800 bar.

^ ^

^

Electronic engine control (MR) with electronic system fixed to the engine, and extensive engine protection functions

^

^

Direct injection with centrally positioned 6-hole injection nozzle.

^

4-valve technology

^

Useful engine brake rpm well over rated rpm, up to 2400 rpm

^

Meets the emission legislation of EURO 3 and EURO M OT/EPA Level 2

^

Turbocharger with charge air cooling

^

V8 with 2 turbochargers

05/03

^ ^ ^ ^ ^ ^

V isco u s fan clutch, electrom agnetic fan clutch and high-speed fan drive on the most powerful engines Rated engine speed 1,800 rpm or 2000 rpm Low maintenance requirement Long maintenance intervals Engine oil and fuel filter located at the front, for easy maintenance Maintenance-free belt drive Can run on FAME / RME (rape methyl ester) or biodiesel, and engine oil changes are halved High reliability and long runtime Low number of component variants, as many parts are the same on both 6 and 8 cylinder engines Rear engine power take-off ex works

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Technical features

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Technical features

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Overview of BR 500 engines with EURO 3 certification Engine model

No. of cylinders/ layout

Output (rpm)

Torque (rpm)

Cylinder bore

Cylinder stroke

[kW/HP (at rpm)]

[Nm (at rpm)]

[mm]

[mm]

Displace ment

Dimensions L x Wx H

Weight

Power/weight ratio

[l]

[mm]

[kg]

[kg/kW]

OM 501 LA

6 Cyl./V

230/313 (1800)

1530 (1080)

130

150

11.95

1190x1020x1130

885

3.85

OM 501 LA

6 Cyl./V

260/354 (1800)

1730 (1080)

130

150

11.95

1190x1020x1130

885

3.40

OM 501 LA

6 Cyl./V

290/394 (1800)

1850 (1080)

130

150

11.95

1190x1020x1130

885

3.05

OM 501 LA

6 Cyl./V

300/408 (2000)

1900 (1080)

130

150

11.95

1190x1020x1130

885

2.95

OM 501 LA

6 Cyl./V

315/428 (1800)

2000 (1080)

130

150

11.95

1190x1020x1130

885

2.81

OM 502 LA

8 Cyl./V

320/435 (2000)

1900 (1080)

130

150

15.93

1530x1195x1080

1125

3.52

OM 502 LA

8 Cyl./V

350/476 (2000)

2100 (1080)

130

150

15.93

1530x1195x1080

1125

3.21

OM 502 LA

8 Cyl./V

350/476 (1800)

2300 (10809

130

150

15.93

1530x1195x1080

1125

3.21

OM 502 LA

8 Cyl./V

370/503 (2000)

2300 (1080)

130

150

15.93

1530x1195x1080

1125

3.04

OM 502 LA

8 Cyl./V

390/530 (1800)

2400 (1080)

130

150

15.93

1530x1195x1080

1125

2.88

OM 502 LA

8 Cyl./V

420/571 (1800)

2700 (1080)

130

150

15.93

1530x1195x1080

1125

2.68

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Technical features

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Overview of BR 500 engines with EUROM OT/EPA Level 2 certification Engine model

No. of cylinders/ layout

Output (rpm)

Torque (rpm)

Cylinder bore

Cylinder stroke

[kW/HP (at rpm)]

[Nm (at rpm)]

[mm]

[mm]

Displace ment

Dimensions L x Wx H

Weight

Power/weight ratio

[l]

[mm]

[kg]

[kg/kW]

OM 501 LA

6 Cyl./V

230/313 (1800)

1530 (1080)

130

150

11.95

1190x1020x1130

885

3.85

OM 501 LA

6 Cyl./V

260/354 (1800)

1730 (1080)

130

150

11.95

1190x1020x1130

885

3.40

OM 501 LA

6 Cyl./V

290/394 (1800)

1850 (1080)

130

150

11.95

1190x1020x1130

885

3.05

OM 501 LA

6 Cyl./V

315/428 (1800)

2000 (1080)

130

150

11.95

1190x1020x1130

885

2.81

OM 502 LA

8 Cyl./V

330/449 (1800)

2150 1200)

130

150

15.93

1530x1195x1080

1125

3.40

OM 502 LA

8 Cyl./V

350/476 (1800)

2300 1200)

130

150

15.93

1530x1195x1080

1125

3.21

OM 502 LA

8 Cyl./V

350/476 (2000)

2100 1200)

130

150

15.93

1530x1195x1080

1125

3.21

OM 502 LA

8 Cyl./V

380/517 (1800)

2400 1200)

130

150

15.93

1530x1195x1080

1125

2.96

OM 502 LA

8 Cyl./V

420/571 (1800)

2700 1200)

130

150

15.93

1530x1195x1080

1125

2.68

OM 502 LA

8 Cyl./V

448/609 (1800)

2700 1200)

130

150

15.93

1530x1195x1080

1125

2.51

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Technical features

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Engine OM 501 LA in cro ss section

N 01.00-2009-50

05/03

N 01.00-2010-50

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Technical features

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Engine OM 502 LA in cro ss section

N 01.00-2011-50

05/03

N 01.00-2012-50

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Technical features

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Series 500<>Cylinder head — port assignment

07.05.2003

Port assignm ent

A B C D E

Coolant Bolts Pressure oil Oil return Plunger, oil return N01.30-2024-12

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cylinder head — port assignment

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Series 500<>Cylinder head

07.05.2003

The individual cylinder heads are made of high-quality molybdenum/cast iron alloy. Each has four stretchthread bolts (M18x2), with which it is bolted to the crankcase. The optimal position for the injection nozzle is the vertical position at the center of the combustion chamber. This ideal arrangement can only be achieved by using multi-valve technology. This consists in arranging the valves in pairs (2 intake, 2 exhaust) around the injection nozzle. A fifth valve is required for the constant throttle or the decompression valve/engine brake. In both cases, these are linked to the exhaust port through an exactly adjusted hole.

N 01.30-2025-02

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cylinder head

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The high-temperature, wear-resistant valve seat rings are inserted deep-frozen into the floor panel. The nozzle holder is inserted in a protective sleeve, which is washed around by coolant and thus individually cooled. The nozzle protective sleeve is sealed by an O-ring against coolant escape, and by the thread and face against gas escape.

N07.03-2035-11

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cylinder head

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Series 500<>Cylinder head mounting

07.05.2003

The cylinder head is tightened in 6 stages The cylinder head bolts do not require retightening. Step 1

Nm

Step 2

Nm

Step 3

Nm

Step 4

Nm

Step 5 Step 6

1

L < 212 mm

W 01.30-0009-02

0 5/0 3

W 01.30-0010-06

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cylinder head mounting

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Series 500<>Cylinder head gasket

07.05.2003

Each cylinder head has a stainless steel insert gasket with scorched elastomer binding, which does not require retightening.

N01.30-2001-50

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cylinder head gasket

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Series 500<>EURO 2 and EURO 3 cylinder heads compared

Cylinder head old version, as of 04/99

mooo^ o65-

In the previous Euro 2 version, the cover surfaces were milled. Since 2000, as part of the «Euro 3» package of measures, the cylinder head surfaces are turned, to a specific surface quality.

Cylinder head, Euro 3 version

07.05.2003

N01.30-2°64-11

The new cylinder heads should be ground to a minimum height of 113.5 mm, by face grinding only. The surface quality (peak-to-valley height and corrugation depth) is to be observed in all cases.

Since 06/2000, this also applies to all Euro 2 V8 and 315 kW V6 engines, and from January 2001 to all other V6 engines.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>EURO 2 and EURO 3 cylinder heads compared

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>EURO 2 and EURO 3 cylinder heads compared

76

Series 500<>Valve assembly

07.05.2003

Gas exchange is improved by 4-valve technology, thus contributing considerably to lower fuel consumption with lower emissions. The intake and exhaust valves are controlled by means of roller tappets, push rods and intake and exhaust rocker arms which are set in a groove in the crankcase with a sliding block, and which operate the intake/exhaust valve pairs through a valve bridge. The rocker arm spindle complete with preassembled rocker arms and rocker arm bearing bracket is bolted to the cylinder head. To keep wear in the whole valve assembly to a minimum throughout its lifetime, the contact surfaces of the valve, valve bridge, the rocker arm thumb, the upset ball socket of the push rod, and the ball head of the adjusting screw, are induction hardened. This is to allow them to support the actuation forces of the high-temperature valve springs, and the effects of inertial forces and cylinder pressures.

N 05.30-2001-50

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Valve assembly

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Cam shaft The camshaft is made of high-strength material, with induction-hardened running surfaces, and has 4 bearings in the OM 501 LA, 5 bearings in the OM 502 LA. Between the bearings are 4 valve timing cams and 2 injection cams for each opposing cylinder pair. The slide ways of the timing cams for the valve and injection roller tappets are supplied with lube oil through additional oil holes in the piston jet pipe.

Nockenwelle Motor OM 501 LA N05.20-2001-50

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Valve assembly

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Adjusting the valve play The valve play checking and setting procedure is the same as for the BR 400, and there are two methods. Method 1 Set the intake and exhaust valves for each cylinder, according to the injection sequence. The cylinder to be set must be at ignition TDC, the parallel cylinder at valve overlap TDC. With this method, the crankshaft must be turned six times in the 6-cylinder engine, and eight times in the 8-cylinder engine.

Method 2 Set the intake and exhaust valves in two crankshaft positions. Adjust when cylinder 1 is at ignition TDC. Adjust when cylinder 1 is at overlap TDC. N05.30-0302-01 P

Valve

Play

Tolerance

Intake

0.40

+ 0.20 / — 0.10

Exhaust

0.60

+ 0.20 / — 0.10

The valve play test tolerance applies only for checking valve play. If valve play is outside the tolerance range, the specified value must be set.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Valve assembly

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General notes on valve adjustm ent Method 1 Set the intake and exhaust valves for each cylinder, according to the injection sequence. The cylinder to be set must be at ignition TDC, and the parallel cylinder at valve overlap TDC.

A E X

Exhaust valve Intake valve Flywheel side

N01.00-0200-01

Engine

Cran ksh aft position

6-cylinder

8-cylinder

05/03

N01.00-0201-01

Cylind er/injectio n sequence

Ignition TDC

1

4

2

5

3

6

Valve overlap

5

3

6

1

4

2

Ignition TDC

1

5

7

2

6

3

4

8

Valve overlap

6

3

4

8

1

5

7

2

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Valve assembly

80

General notes on valve adjustm ent Method 2 Set the intake and exhaust valves at two crankshaft positions, as shown in the table.

A E X

Exhaust valve Intake valve Flywheel side

N01.00-0200-01

Engine

8-cylinder

05/03

6-cylinder

8-cylinder

First set cylinder 5 at valve overlap TDC (cylinder 1 at ignition TDC), then cylinder 1 at valve overlap TDC (cylinder 5 at ignition TDC).

First set cylinder 6 at valve overlap TDC (cylinder 1 at ignition TDC), then cylinder 1 at valve overlap TDC (cylinder 6 at ignition TDC).

Cran ksh aft position

6-cylinder

N01.00-0201-01

Cylind er/injectio n sequence 1

2

3

4

5

6

7

8

Cylinder 5 valve overlap

I/ E

E

I

E

—

I

Cylinder 1 valve overlap

—

I

E

I

I/ E

E

Cylinder 6 valve overlap

I/ E

E

I

I

E

—

E

I

Cylinder 1 valve overlap

—

I

E

E

I

I /E

I

E

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Valve assembly

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Valve assembly

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Series 500<>Pump-line-nozzle injection system (PLD)

07.05.2003

Engines of the OM 500 model series use the direct fuel injection process. The injection process is performed by the newly developed pump-line-nozzle (PLD) system, controlled by an electronic engine management system that has also been newly developed. In the PLD system, fuel is delivered to the injection nozzle by individual unit pumps over short, rigid high-pressure injection lines, and through the pressure pipe connection screwed into the cylinder head. The connection to the nozzle and nozzle holder is located centrally at the cylinder, and is integrated with, and removable from, the cylinder head. A unit pump fitted for each cylinder is located directly on the crankcase.

N07.02-2018-50

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Pump-line-nozzle injection system (PLD)

83

The electronic engine management system controls the injection timing point and quantity injected individually per cylinder, by means of solenoid valves. Separation of the high pressure pump and injection nozzle made it necessary to develop a high pressure injection line of special tube material with a surface hardened by internal high pressure forming, able to support continuous injection pressures over 2000 bar. With high pressure injection (peak pressures up to 1800 bar) together with the central, vertically positioned nozzle with 8 or 6 injection orifices and flat combustion chamber cavity in the piston, outstanding particulate values are achieved.

Advantages over the Pum p-Nozzle system O No overhead camshaft — therefore lower space requirement and reduced engine height — lower noise emission O On the V-engine, only one camshaft needed, which controls both cylinder banks. — Weight saving O Locating the camshaft in the center of the crankcase means there is optimal power absorption. With an overhead camshaft, measures would be necessary for strengthening the cylinder head. O Easy to repair — Individual cylinder heads, which are all identical — Compact unit pumps, which are simple to replace — Inexpensive replacement due to separate pump and nozzle

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Pump-line-nozzle injection system (PLD)

84

Pressure pipe connection and nozzle holder location

Connection to the nozzle holder and injection nozzle (positioned vertically at the center of the cylinder), is through a fixed, preassembled pressure pipe connection with integral pin-type filter. The nozzle holder with 8 or 6-hole injection nozzle is held in a protective sleeve by means of a clamping claw supported on the nozzle holder and constant throttle cap, and attached with a central screw. The seal at the nozzle protective sleeve consists of a copper spacer or sealing sleeve. For nozzle holder positioning, the clamping claw grips a locating pin fixed into the nozzle holder cap. The pressure pipe connection is attached with a press-in ball fastening. 1 3 4 5.1 5.2 6 7 8 9 10

Injection line, 30 [Mm] Pressure screw, 40 [Mm] O-ring Pressure pipe connection with anti-twist lock (press-in ball fastening) Pressure pipe connection without anti-twist lock Nozzle holder combination O-ring Screw, 50 Mm, < 91 mm Retaining clip Sealing ring

11

Constant throttle cap

05/03

W 07.03-1006-06

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Pump-line-nozzle injection system (PLD)

85

Rem oving/installing the nozzle holder combination 1 2 3 4 5.1 5.2 6 7 8 9 10 11 12 13 L

Injection line, 30 Nm Leak fuel line, 15 Nm Pressure screw, 40 Nm O-ring Pressure pipe connection with anti-twist lock (press-in ball) Pressure pipe connection without anti­ twist lock Nozzle holder combination O-ring Screw, 50 Nm Retaining clip Sealing ring or sealing sleeve Constant throttle cap Adapter 904 589 00 63 00 Extractor 355 589 01 63 00 Shank length of screw (8), < 91 mm

W 07.03-1005-06

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86

To remove 1.

Risk of explosion due to gas ignition, risk of poisoning by inhaling or absorbing fuel, or risk of injury to skin and eyes through contact with fuel.

2.

Remove the cylinder head cover

3.

Remove leak fuel line (2) from cylinder head

4.

Remove injection line (1)

5.

Unscrew pressure screw (3) and remove pressure pipe connection (5).

6.

Remove retaining clip (9)

7.

Fit the adapter (12) and extractor (13) to the inside thread (M of nozzle holder combination (6) Take out the nozzle holder combination (6)

8. 9. 10.

Fire, sparks, naked flames, smoking are forbidden. Only store fuel in suitable and appropriately marked containers. Wear protective clothing if handling fuel.

Adapter: 904 589 00 63 00 Extractor: 355 589 01 63 00 The nozzle holder combination should not be disassembled. If worn or faulty, the nozzle holder combination must be replaced.

Remove the adapter (12) and extractor (13) from nozzle holder combination (6) Take out the sealing ring (10) To install

1.

Measure the shank length of screw (8).

H If the maximum shank length is exceeded, replace the screw. MB Standard 10105 screws are generally to be replaced by screws with an MB Part No. on the screw head.

2.

Insert a new O-ring (7) at nozzle holder combination (6)

3.1

Place the new O-ring (10.1) at nozzle holder combination (6)

H Grease the O-ring. H Up to engine End Number 197928 Note the installation location and thickness of the sealing ring: the smaller ring surface should point towards the nozzle holder combination. Grease the sealing ring.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Pump-line-nozzle injection system (PLD)

87

3.2

Press new sealing sleeve (10.2) onto nozzle holder combination (6)

H From engine End Number 197928 Before pressing on the new sealing sleeve, the contact surface of the sealing sleeve should be cleaned to remove combustion residues (using a wire brush or ultrasonic equipment, for example). 1 Clean the nozzle holder combination.

H Grease the sealing sleeve. 4.

Install nozzle holder combination (6)

5.

Mount the retaining clip (9.1 or 9.2), 50 Nm

6.

Place the new O-ring (4) at pressure pipe connection (5).

7.

Fit the pressure pipe connection (5.1 or 5.2) and tighten pressure screw (3),40 Nm

H Note installation location of nozzle holder combination at the pressure pipe connection hole. Twist the nozzle holder combination with retaining clip (9) into the cylinder head until the retaining clip (9.1 or 9.2) clips onto the locating pin on the cap of constant throttle (11). |Nm|

H Grease the O-ring. H

Pressure pipe connections with anti-twist lock (5.1, press-in ball) sho>uld not be fitted to cylinder heads without a groove (arrowed). The ball (ar rowed) must be inserted in the groove (arrowed). Da maged pressure pipe connections with an anti-twist lock can be rep laced by the modified pressure pipe connection without anti-twist lock (5. 2).

H Moisten the pressure pipe connection around the taper seal with eng ine oil. m 8.

Install the injection line (1)

9.

Fit the leak fuel line (2), 15 Nm

10.

Fit the cylinder head cover

05/03

m

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W07.03-1020-01

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W 07.03-1019-06

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Special tools

QpiJ 355_589_01_63_00

904_589_00_63_00

906_589_00_63_00

Rem arks: 3.) 4.)

Extracting tool 906 589 02 63 00 is now usually supplied together with the extension. From April 2003, for new orders under the existing number, special tool 906 589 00 63 00 is supplied with modification to Part 1. To extend existing tools, the modified Part 1 can also be ordered separately under number 906 589 00 63 01.

906_589_02_63_00

05/03

Extracting tool extension

906_589_02_63_01

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Pump-line-nozzle injection system (PLD)

90

Series 500<>Removing/installing the MR/PLD unit pump

07.05.2003

W 0 7 .15-1057-09

1 2 05/03

M R /P LD unit pump O-ring (black)

3 4

O-ring (brown) Protective sleeve 541

589 01 14 00

5 6

Splined bolt, 65 Nm Cable duct with engine wiring harness

7 8

Extractor 355 589 01 63 00 Injection line, M 16×1.5, 50Nm

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Rem oving/installing the M R /P LD unit pump

91

Rem oving/in stallin g 1.

Risk of explosion due to gas ignition, risk of poisoning by inhaling or absorbing fuel, or risk of injury to skin and eyes through contact with fuel.

2.

Remove the charge air pipe

3.

Remove injection line (8)

Stop up the orifices in the nozzle holder combination and M R/PLD unit pump (1).

4.

Clean the crankcase around the MR/PLD unit pumps (1).

Cover the intake orifices in the cylinder heads.

5.

Remove engine wiring harness (6) at all M R/PLD unit pumps (1) on left or right.

To do this, loosen the screws on the solenoid valve and detach both clip fasteners.

6.

Identify the M R/PLD unit pump (1) for the cylinder concerned

Only if removing more than one or all M R/PLD unit pumps

7.

Loosen the splined bolts (5)

For reasons of safety, the splined bolts should be unscrewed by only about 4 to 5 mm; the MR/PLD unit pump is under spring load. Installation: Press the M R/PLD unit pump into the crankcase with the splined bolts, tightening slowly and alternating between bolts. Tighten the splined bolts to 65 Nm

8.

Fit the extractor (7) to MR/PLD unit pump (1)

Extractor: 355 589 01 63 00

05/03

Fire, sparks, naked flames, smoking are forbidden. Only store fuel in suitable and appropriately marked containers. Wear protective clothing if handling fuel.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Rem oving/installing the M R /P LD unit pump

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9.

Pull out the MR/PLD unit pump (1) with the extractor (355 589 01 63 00) up to the bolt heads

Remove the fuel lines or fuel overflow valve on the crankcase if necessary. Banjo bolt of fuel line to port in crankcase, 50Nm. Banjo bolt of fuel line to fuel overflow valve, 50 Nm. If stuck, the M R/PLD unit pump should not be pressed out at the solenoid valve and housing flange. Carefully press out the M R/PLD unit pump at the cutout (arrowed) in the unit pump housing. Installation: Lightly oil the unit pump body, O-ring surfaces (2, 3), and hole in the crankcase with engine oil. Do not tilt the MR/PLD unit pump when inserting in the crankcase. Carefully press in the M R/PLD unit pump by hand, to a depth of about 4 mm. If the unit pump cam on the camshaft is at the top, turn the engine by a half-revolution (in direction of rotation).

10.

Unscrew the splined bolts (5) and pull out the M R/PLD unit pump (1)

Installation: Carefully remove dirt and paint residues from the sealing surface (arrowed) of the M R/PLD unit pump and crankcase.

11.

Check the MR/PLD unit pump

Check the roller on roller tappet; if there is only slight scoring or scratching, the MR/PLD unit pump can be used again. If there is deep scoring, scratching, or sanding spots: Install a new M R/PLD unit pump

12.

Remove O-rings (2, 3) from the MR/PLD unit pump (1)

Installation: Clean the radial groove in the unit pump body. Push protective sleeve (541 589 01 14 00) over the unit pump body, coat the new O-rings with engine oil; slip the black O-ring, (2) over the protective sleeve into the top groove, then the brown O-ring (3) into the lower groove. Avoid twisting the O-rings when fitting into the grooves.

13.

Install in the reverse order

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Unit pump classificatio n The BR 457, 500 and 900 unit pumps are classified at manufacture.

AXO R

When each pump is installed in the engine on the assembly line at Mannheim, its classification is registered and stored in the MR electronic system. To ensure smooth engine running, the classification values are taken into account when distributing the fuel quantity (injection timing). To ensure that smooth engine running continues after unit pumps are replaced or modified for diagnostic purposes, the unit pump classification must be assigned to the cylinder. An input error m ay lead to rough engine running and overloading of individual cylinders. Then reset the individual cylinder torque control to «0».

MR

Replace unit pump Cylinder

Code

1

C y lin d e r 1

X-XXX-XXX -X X -X X X X X

2

C y lin d e r 2

X-XXX-XXX -X X -X X X X X

3

C y lin d e r 3

X-XXX-XXX -X X -X X X X X

4

C y lin d e r 4

X-XXX-XXX -X X -X X X X X

5

C y lin d e r 5

X-XXX-XXX -X X -X X X X X

6

C y lin d e r 6

X-XXX-XXX -X X -X X X X X

Note: The user m ust read off the unit pump number on the unit pump, and enter it for the corresponding cylinder. Only enter the unit pump number for pumps being replaced.

To confirm, press F3.

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The classification is coded as a 14-digit number (C) on the unit pump model plate. The code is entered through the «Replace Unit Pump» menu in DAS. A028 074 60 02A= MB number B= Certification number C= Unit pump number (classification) D= Bar code E, G, H = Manufacturer information F= Manufacturer bar code

SE 9401

N07.02-2028-01

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Rem oving/installing the M R/PLD unit pump

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Sealing the interm ediate plate of the unit pump

W 0 7 .15-1058-09

1

Pump body

2

Seal

5

Model plate

O-ring

1.1

Anchor plate

3

Intermediate plate

6

Screw

O-ring

1.2

Crosspiece

4

Solenoid

7

Stop plate

05/03

10

®

Screw driver bit

11

^ S le e v e

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**

To remove

®

Utmost cleanliness should be ensured whenever working on the unit pumps.

1 2

Remove the MR/PLD unit pump Remove O-rings (8,9,) from the unit pump (1)

3

Push the sleeve (11) onto unit pump (1)

4

Clean the upper part of the MR/PLD unit pump.

@ First clean the bottom part of the pump body (1).

@ So that dirt will not get into the orifices. S @ Carefully remove paint residues on the sealing surfaces of the MR/PLD unit pump.

H The high pressure orifice must be closed off. No dirt or cleaning agent should be allowed to penetrate into the pump body (1). 5

Identify the intermediate plate (3) (arrow A) for the pump body (1) and place the MR/PLD unit pump at the stop plate.

6

Loosen the screws (6), and remove solenoid (4) together with intermediate plate (3) and model plate.

7

Remove intermediate plate (3) and model plate (5) from solenoid (4).

8

Take out sealing rings (2) and clean intermediate plate (3)

9

Identify the crosspiece (1.2) and anchor plate (1.1) for pump body (1) (arrow C).

@

Use a scriber or touch-up pencil, never a stamping tool.

H First remove paint residues from the screw heads with a scriber (arrow B).

S H Clean the sealing surface of the solenoid. @ Do not damage the sealing surfaces. @ Use a touch-up pencil, never a scriber or stamping tool. The crosspiece should not be moved or turned.

10

Apply cleaning spray to the sealing surfaces of pump body (1), crosspiece (1.2) and anchor plate (1.1).

@ Clean the parts carefully. H Do not remove paint residues from the pump body (1), these will be needed for locating the intermediate plate (3).

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Rem oving/installing the M R/PLD unit pump

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11

Take off stop plate (7)

@ Remove paint residues around the contact surface of the screw heads. Do not remove the protective foil on the model plate.

12

Clean the model plate (5)

W M

To install

13

Place new stop plate (7) under the pump body (1).

14

Insert new seals (2) in the intermediate plate (3).

15

Place intermediate plate (3) on pump body (1).

H Protect the seals with grease @ Pay attention to the identification marks on the crosspiece (1.2) and anchor plate (1.1) for pump body (1). The cutouts (arrows D) at the opening in the intermediate plate must point towards the crosspiece (1,2).

H The paint residues are used to locate intermediate plate (3) on pump body (1). 16

Insert the solenoid (4) on intermediate plate (3).

17

Assemble the model plate (5), solenoid(4), intermediate plate (3), pump body (1) and stop plate (7) and fasten with new screws (6).

HH Tighten the screws crosswise.

18

Take off sleeve (11)

19

Install MR/PLD unit pumps

S 904 589 02 10 00 S 001 589 80 21 00 S 541 589 01 14 00 H Fit new O-rings (8,9), following the installation specification.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Rem oving/installing the M R/PLD unit pump

99

Engine 541.9, 542.9

Nm M R/PLD unit pump Screw, solenoid valve to MR/PLD unit pump

Step 1 [Nm]

2

Step 2 [Nm]

4

Special tools

Torque screwdriver

05/03

001_589_80_21_00

Sleeve

541_589_01_14_00

Screwdriver bit

904_589_02_10_00

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Rem oving/installing the M R/PLD unit pump

100

07.05.2003

Series 500<>EURO 2 and EURO 3 pistons

Euro 2 piston

mo^ o^ os1-11

From 02/00, quality improved by reduced ring wear and oil consumption and optimized bore profile for longer service life.

05/03

Euro 3 piston

n°3.1o-2°52

From 03/00 for Euro 3 engines: Modified combustion chamber, use of hub liner to prevent strain cracks and improve cylinder properties. The radial grooves and piston rings have also been modified to further reduce oil consumption.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>EURO 2 and EURO 3 pistons

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Series 500<>Connecting rod

07.05.2003

The steel connecting rod is partially forged. The separation of connecting rod from bearing cap is made by ‘cracking’. Compared with the conventional, costly separating process, ‘cracking’ brings high dimensional stability to the large connecting rod eye. The separation point at the large connecting rod eye is set obliquely. Connecting rod and bearing cap are linked positively and frictionally with each other by two stretch-thread bolts. The ignition power is absorbed evenly at the small, trapezoidal connecting rod eye by a solid bronze bushing, which is supplied with sufficient lube oil from the large connecting rod eye through a pressure oil hole.

N03.10-2002-03

Due to the intermediate flange needed on the crankshaft in the V6 engines, the width of the connecting rod at the connecting rod eye is fixed at 34 mm. In the V8 engines, the width is 37 mm.

05/03

N 03.10-2021-02

From about 06/98, there has been a modification to the oil feed at the small end bearing. Two oil holes (D) have been made in the connecting rod eye for the oil supply to the small end bearing. The long oil hole (C) for the pressure oil supply to the small end bearing has been removed.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Connecting rod

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Series 500<>Crankcase

07.05.2003

Design features: * Compact design, by integrating the oil cooler, coolant pump coil, unit pumps, and the coolant, fuel and oil ducts. * Highly rigid alloy cast iron. * Rigid crankcase deck and stable liner bottom collar support, with low-set threads on the cylinder head bolts. This results in low-warp absorption of the thread connection and ignition forces by the rigid collar of the wet cylinder liner. * Rigid side walls extending well below the center of the crankshaft, and bolted together with the crankshaft bearing caps.

N01.40-2001-50

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Crankcase

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Series 500<>Cylinder liners

07.05.2003

A tombac ring (0.15 mm) is placed under the upper cylinder liner collar support where the thermal load is high, and forms the seal on the water side. The lower end is sealed by two high-temperature, oval Viton rings, on both the water and oil side. 1 2 3 4,5

Crankcase Cylinder liner Tombac ring Oval Viton ring

N 01.40-2019-03

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cylinder liners

104

M odifications From about 04/99, a new cylinder liner has been installed, in conjunction with a modified crankcase. The new cylinder liners have a groove (arrowed) under the collar. Two holes have also been made in the crankcase (arrowed) under the cylinder liner seat. This improves the cooling around the piston top land and the first piston ring

N 01.40-2020-02

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Com parison of cylinder liners

N 01.40-2061-09

A

Standard production up to around 0 4 / 9 9 in conjunction with crankcase without cooling holes

05/03

B

Repair in conjunction with crankcase without cooling holes

C

Standard production up to around 0 4 / 9 9 in conjunction with crankcase with cooling holes

D

EURO 3 standard

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cylinder liners

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Series 500<>EURO 2 and EURO 3 cylinder liners compared

Euro 2 cylinder liner

N01-10-2070-11

Euro 3 cylinder liner

07.05.2003

N01-30-2071-

Modification to Euro 3 standard As part of «Quality offensive 2000», the crankcase in engine model series BR 500 has been modified starting from 07/00. Partially hardened raised bead liners are now used, as in Euro 3. The overall length of the cylinder liner was also shortened in order to adapt the pre-worked dimensions to the finished part.

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>EURO 2 and EURO 3 cylinder liners compared

107

Series 500<>Crankcase ventilation system

07.05.2003

An oil breather is fitted to the timing case cover, as part of the general plan to cut exhaust gas emissions and help reduce engine oil consumption. Blow-by gases pass from the combustion chamber over the piston rings into the crankcase, where they are mixed with tiny oil droplets in the oil vapor. To stop oil vapor escaping into the atmosphere, the vapor is drawn off, cleaned and recycled back to the engine intake side. A vacuum diaphragm controls the pressure in the engine oil gallery. A filter element keeps the proportion of oil vapor to a reduced level. The oil filtered out is passed back into the oil gallery through a return element integrated with the ventilation system.

N01.20-2009-12

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W 01.20-1004-02

Note on diagnosis: If there is repeated oil leakage from the engine, the de-oiling element must be checked to ensure that it is functioning properly, i.e. the filter insert must be examined for contamination or damage.

Important! W henever the oil filter is changed, the oil separator insert of the engine ventilation system m ust be replaced as well!

05/03

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D efective vacuum diaphragm

GT_01_40_00_0003

05/03

GT_01_40_00_0004

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Crankcase ventilation system

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05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Crankcase ventilation system

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Series 500<>Fuel system

07.05.2003

Location of the fuel filter bowl

N47.20-2033-02

W 07.57-0002-06

The fuel filter bowl is fixed to the oil filter oil filter housing, but has its own feed lines that can be removed separately. 05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Fuel system

112

Fuel system — real 4 5 6 7 8 10

Fuel heat exchanger Fuel pump (KFP) Fuel filter Nozzle holder combination PLD unit pumps (Y6 to Y13) Overflow valve

A B C

Fuel feed/suction side Fuel feed/pressure side Fuel high pressure side (injection line) after PLD unit pumps Fuel return after unit pump Fuel flush quantity (fuel short circuit) Fuel return/ leak fuel

D E F

W 07.00-1001-06

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Fuel system — sym bolic The low-pressure fuel system has been specially designed to meet the requirements of the high-pressure injection system with individual unit pumps on V-engines. Unlike on conventional injection systems, to ensure stable injection, a high pre-pressure is necessary in the low-pressure system and a large flush volume for cooling the control valve solenoids in the unit pumps.

1 1.1 2 3.1 3.2 4. 5. 5.1 6. 6.1 6.2 7. 8. 9. 10. 10.1 11.1 11.2 12

Fuel tank Fuel strainer (800 ^m) Fuel prefilter (KVF 300 ^m ) with manual fuel feed pump Plug-on valve in fuel feed (locked open) Plug-on valve in fuel return (locked open) Fuel heat exchanger Fuel pump (KFP) Pressure relief valve (9.0 — 12.0 bar) Fuel filter (5 ^m) Fuel filter drain valve Constant vent in fuel filter (0.7 mm) Nozzle holder combination PLD unit pumps (Y6 to Y13) Banjo union with constant vent (0.7 mm) Overflow valve (2.0 bar up to engine No. 092 407, 2.65 bar from engine No. 092 408) Throttle (3.1 mm) in overflow valve Fuel feed connector (in frame) Fuel return connector (in frame) Throttle (0.5 mm) in flame starting system fuel line

B10 R3 Y5

Fuel temperature sensor ( no lo n g er in s ta lle d ). Flame glow plug Flame starting system solenoid valve

05/03

T e s t p o in ts

I

II

III IV

V

Fuel pressure after fuel filter Idle speed: 1.8 — 2.8 bar up to engine No. 0924 07, 2.2 — 3.2 bar from engine No. 092 408 Cutoff speed: 4.5 — 5.5 bar Fuel pressure after fuel pump Idle speed: 2.1 — 3.0 bar Cutoff speed: 5.0 — 6.0 bar (limit value « 6,5 bar) Fuel intake pressure before fuel pump Cutoff speed: 0.35 to 0.25 bar Fuel return quantity at fuel tank Idle speed: 0.6 — 1.0 l/m in Cutoff speed: 1.0 -1.6 l/m in Low pressure-fuel system leaktightness Test pressure 5.5 b ar/test period 5 minutes: no pressure drop Fuel return quantity at nozzle holder combination Idle speed: oil-damp Cutoff speed: drops only at most.

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W 07.15-1077-09

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Fuel prefilter with heated water separator In countries where the fuel is considered heavily contaminated and with high water content, an additional fuel filter with integrated water separator (including manual feed pump) is highly recommended. V eh icles that are operated in countries of Eastern Europe, or filled with fuel from those countries, m ust be fitted with a prefilter.

Advantages to the custom er: • Increased durability of the injection system • Long maintenance intervals despite difficult operating conditions • Greater economy through shorter vehicle downtimes.

W47.20-1006-11

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Ch ecking the low pressure fuel system Rem oving/in stallin g 1.

Risk of explosion due to gas ignition, risk of poisoning by inhaling or absorbing fuel, or risk of injury to skin and eyes through contact with fuel.

Fire, sparks, naked flames, smoking are forbidden. Only store fuel in suitable and appropriately marked containers. Wear protective clothing if handling fuel. If components are soiled, clean them and dry off. Let the engine run for about 2-3 minutes at cutoff speed. If damaged or leaky, install new components, or retighten to the tightening torque.

2.

Carry out a visual inspection of all fuel lines, threaded connections and components

3.

Check the fuel prefilter insert

Clean the fuel prefilter if necessary.

4.

Replace fuel filter insert if necessary.

5.

Check the fuel filter insert Open the cap on the fuel tank

6.

If stationary rpm limitation is parameterized, set a high value

Connect diagnostic test equipment. Only on engines with stationary rpm limitation, set this up to 4000 rpm. Note down the rpm limitation value entered. Installation: Set the rpm limitation parameter back to the original value with the test equipment.

Testing 1.

05/03

Test conditions

If a Racor fuel prefilter is installed, detach the fuel lines to the prefilter and put the fuel system in the standard production configuration. The engine must be at operating temperature. Fuel temperature in the fuel tank < 40°C. Collect any escaping fuel. When testing, the flowing fuel must be free of bubbles.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Fuel system

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Testing fuel pressure Attach pressure gauge (1) with high pressure hose (2) and fuel line (5) to the fuel filter housing bowl (6). When testing, do not connect the fuel line to the flame starting system.

1. 2. 3. 4. 5. 6.

Tester 541 589 02 21 00 High pressure hose 123 589 04 21 18 Double banjo bolt M16 x 1.5, 50 Nm Banjo union with external thread Fuel line Fuel filter bowl

W 0 7 .15-0127-11

Testing 2.

05/03

Connect the tester/gauge to the low pressure fuel system

Fuel pressure test at the outlet of the fuel filter bowl (clean fuel side)

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Fuel system

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Testing the fuel return quantity • Detach the fuel return line (1) at the sensor of the fuel level gauge and remove the O-ring from the plug socket. • Do not damage the O-ring. • Connect the fuel return line (1) withthesee-thrufuelline (2). • With the engine running, check thesee-thru fuelline (2)for air bubbles • If there are air bubbles, check the fuel system for leaks. • Check the fuel return quantity

Testing the fuel system for leak points: • Detach both lines from the tank. • Stop up the return line • Fit a shutoff cock to the intake line • Connect an external air supply. • Set a test pressure of 5.5 bar (read off the pressure on fuel pressure gauge) • No pressure loss over the test period (5 min). W 0 7 .15-0126-11

Testing 3.

05/03

Connect the tester/gauge to the low pressure fuel system

Measurement of fuel return quantity at the fuel tank

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Fuel system

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Testing the fuel intake pressure at the fuel feed pump • Attach the tester (2) with test line (2.1) and fuel feed line (3) to fuel feed pump (1). • Unclip the free test line (2.1) with clamp (5). Put the tester (2) at the frame and fasten.

1 2 2.1 3 4.1 4.2 5

Fuel feed pump Tester 617 589 04 21 00 Test lines Fuel feed line Double banjo bolt M16 x 1.5, 50 Nm Banjo union Clamp 000 589 40 37 00

Testing 4.

05/03

Connect the tester/gauge to the low pressure fuel system

Fuel intake pressure before the fuel feed pump

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Fuel system

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Fuel system

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Checking the fuel system In w hat circu m stances m ust the fuel pressure be checked? Poor startup, poor performance

W hat can cause the fuel pressure to be too low? Dirty prefilter, dirty fuel filter, faulty overflow valve, fuel system is drawing in air, kink in feed line from tank, intake line at fuel tank sensor, check valve in fuel feed, leak in filter bowl at the return flow, faulty feed pump

W hat can cause the fuel pressure to be too high? Faulty overflow valve, kink in return flow line, check valve in the fuel return line, fuel tank sensor clogged

W hat other operations should be carried out? Check the fuel system at and in the engine for leaktightness, check the fuel intake pressure, measure the fuel return quantity and check for air bubbles.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Fuel system

123

Series 500<>Oil cooler and oil filter housing — component locations

07.05.2003

T a sk 1 Assign the correct numbers to the components in the diagram. Refer to the existing workshop documentation.

The following components are integrated in the aluminum die-cast housing of this assembly: 1 2 3 4 5 6 7 8 9 10 11

Full-flow oil filter Filter drain valve Filter bypass valve Oil temperature sensor Oil pressure sensor Oil/water heat exchanger (flat pipe) Coolant temperature sensor Connection for bypass filter(outlet) Connection for bypass filter(inlet) Riser Connection for oil filling

N 18.20-2020-05

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124

Oil filter housing with oil filter, drain valve, filter bypass valve, oil/water heat exchanger with fuel filter installed.

The m ost im portant com ponents of the engine lubrication / cooling system are: — Oil pan — Oil pump with pressure relief valve — Oil retention valve (return flow check valve) — Oil/water heat exchanger — Oil filter with drain valve and filling valve — Filter bypass valve — Main oil duct, oil ducts and oil lines — Oil spray nozzles — Oil temperature sensor and oil pressure sensor — Oil level sensor — Rocker arm spindle, rocker arm with oil hole

N 18.20-2020-05

Engine lubrication reduces the mechanical wear on moving parts and makes their work easier. At the same time, the parts are cooled and impacts absorbed. Oil pump The oil pump is in the form of a gear type oil pump, with a gear width of 43 mm on the 541.9 engine and 49 mm on the 542.9 engine. The gear type oil pump is located at the rear of the crankcase. The oil pump is driven by the crankshaft. It delivers the engine oil from the oil pan through an oil duct to the oil retention valve, then to the lateral main oil duct and the oil/water heat exchanger.

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125

Pressure relief valve The pressure relief valve is located under the oil pump and maintains constant oil pressure. If too much oil is delivered at high engine speeds, the pressure relief valve opens and allows the engine oil to flow directly from the oil pump back to the oil pan. Oil retention valve (return flow ch eck valve) The return flow check valve is placed at the right rear in the crankcase and is intended to prevent engine oil flowing back into the oil pan when the engine is stopped. The oil ducts are therefore always filled with oil. When the engine is restarted, this ensures that components always receive optimal lubrication from the beginning. O il/w ater heat exchanger The oil/water heat exchanger is located in a housing assembly on the front of the crankcase, with integral oil/water heat exchanger and oil filter. The engine oil flows through the plates (12 elements) in the oil/water heat exchanger, and these are washed around by the engine coolant. Since the engine coolant is at a considerably lower temperature than the engine oil, the coolant absorbs the heat from the engine oil and cools it down to engine operating temperature. During cold starts, the engine oil is warmed up by the surrounding coolant through of the oil/water heat exchanger. Oil ducts and oil lines Oil ducts are integrated into the crankcase and cylinder heads. The oil pressure and oil return lines to the turbocharger (or both turbochargers) and long-life oil filter housing (special equipment) are located externally. The oil retention valve is located at the start of the lateral main oil duct, which is placed on the right of the crankcase. From two further oil ducts located centrally at camshaft level in the crankcase, other oil ducts (Y and cross-drillings) go to the individual oil spray nozzles, camshaft bearing, crankshaft main bearing, MR/PLD unit pumps and the individual cylinder heads. Engine oil is fed from the main oil duct, through an oil duct system in the rear wall of the crankcase, to the turbocharger oil pressure line and both compressor bearings. This oil duct system also supplies engine oil to the oil spray nozzle for the power take-off (special equipment). On engines without power take-off, a screw plug is fitted in place of the oil spray nozzle. The oil ducts in the crankcase are partly closed with screw plugs or balls. The connecting rod bearing is supplied with engine oil through oil ducts integrated into the crankshaft. Engine oil is delivered to thebearing brackets of the individual rocker arm spindles through holes in the cylinder head gasket and the oil duct in the cylinder head. From the rocker arm spindle bearing bracket, oil is supplied to the rocker arm spindle and all the rocker arms. It then passes through the oil holes in the rocker arms and also supplies the valve assembly. The oil then flows back to the oil pan through oil return holes in the cylinder head and crankcase.

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126

Oil filter The oil filter housing is fitted to the left front of the crankcase. It contains an oil filter insert, made of paper. The oil filter insert is clipped into the oil filter cover and is replaced from the top. When the filter cover is unscrewed, engine oil in the filter housingflows through the drain valve back into the oil pan. Drain valve The drain valve is located in the oil filter housing under the filter insert, and opens when the filter cover is unscrewed.This ensures a cleaner filterchange and less environmental pollution by reducing the amount of residual oil in the old filter. Filter bypass valve The filter bypass valve (release pressure 2. 3 — 3. 0 bar) is located in the housing assembly under the oil/water heat exchanger and connected with the oil filter through an oil duct. The normal position of the filter bypass valve is closed. If the oil filter insert is clogged, the pressure increase in the filter housing opens the filter bypass valve. This ensures that the engine is lubricated, although the engine oil passing through the bypass valve is unfiltered. Filling valve The filling valve is placed at the bottom of oil filter housing and is closed with a screw plug (M33x2). Through this valve, engine oil can be poured into the engine assembly, and after repairs to the engine oil system before starting the engine. Oil sp ray nozzles The oil spray nozzles are located in the crankcase, one per cylinder. Oil is supplied to the oil spray nozzles through both oil ducts. The nozzles spray engine oil continuously under the piston crowns, thus cooling them, while at the same time the piston crowns are lubricated by engine oil dripping through an opening in the top of the connecting rod. The oil spray nozzles also spray engine oil through another hole onto the valve and unit pump cams on the camshaft. Oil tem perature sensor and oil pressure sensor The oil temperature and oil pressure sensor is screwed from the front into the housing assembly under the oil/water heat exchanger, and connected with the oil filter through an oil return duct.

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127

Series 500<>Oil circuit

07.05.2003

Engine lubrication reduces the mechanical wear on moving parts and makes their work easier. At the same time, the parts are cooled and impacts absorbed.

The most important components of the engine lubrication / cooling system are: — Oil pan — Oil pump with pressure relief valve — Oil retention valve (return flow check valve) — Oil/water heat exchanger — Oil filter with drain valve and filling valve — Filter bypass valve — Main oil duct, oil ducts and oil lines — Oil spray nozzles — Oil temperature sensor and oil pressure sensor — Oil level sensor — Rocker arm spindle, rocker arm with oil hole

N 18.00-2011-50

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Series 500<>Engine oil system

07.05.2003

Shown on 541.9 engine A B C 1 2 2.1 2.2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Engine oil cleaned Engine oil dirty Oil filter bowl installation location Oil pan Oil pump Pressure limiting valve Oil pump strainer with oil intake tube Oil retention valve Main oil duct O il/w ater heat exchanger Oil filter housing Oil filter bypass valve Oil duct Oil spray nozzle Main con-rod bearing on crankshaft Cam shaft bearing Rear oil duct Oil duct in cylinder head R o cke r arm spindle, rocker arm with oil hole Oil return flow duct from cylinder head Oil pressure line to turbocharger Oil return line from turbocharger Crankshaft in com pressor Oil spray nozzle for power take-off special equipment

W 18.00-1006-06

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Series 500<>Oil spray nozzle

07.05.2003

If an oil spray nozzle is damaged or incorrectly adjusted, the piston is no longer cooled correctly. This can cause piston seizure.

Note: It is no longer permitted to adjust the oil spray nozzle. The oil splasher pipe is soldered in, and the adjustment process could cause initial damage.

W 18.00-0004-09

05/03

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Tightening pattern for the oil pan bolts

Observe the tightening torque and sequence for the oil pan bolts, always starting from position No. 1 (see tightening pattern). To ensure even contact (no turning of the oil pan gasket), all tightening stages must be observed.

05/03

Engine 541 tightening pattern

W 01.45-1008-10

Engine 542 tightening pattern

W01.45-10° 9-10

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131

Engine 541.9, 542.9

Nm Oil pan Oil pan bolt to crankcase

05/03

Light alloy

[Nm]

55

Plastic

Stage 1

[Nm]

0.5

Plastic

Stage 2

[Nm]

10

Plastic

Stage 3

[Nm]

35

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Oil spray nozzle

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Oil spray nozzle

133

Series 500<>Water guide

07.05.2003

Internal w ater guide Coolant is delivered from the water pump coil integrated into the front of the crankcase, and flows through the plate-type oil cooler in the oil filter housing, which projects into the central water channel. From the central water channel in the crankcase, each cylinder is supplied with water uniformly through individual, tangential water channels. The water flow around the cylinder liners is divided in two by a fin. This ensures the coolant flow in the lower cylinder area and an even main flow in the upper area, for intensive cooling of the piston TDC areas where the thermal load is high. Coolant flows through the drillings in the crankcase into the cylinder head. Particularly intensive cooling of the valve lands and nozzle area is achieved by special forming of the water jacket in the cylinder head.

N20.00-2002-50

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Coolant flows back through openings in the crankcase into two return channels cast into the crankcase, one per cylinder bank. The return channels are connected to a cross-duct integrated in the oil filter/oil cooler housing assembly, through which coolant flows back into the double thermostat housing joined to the coolant pump. If a retarder is fitted, the coolant for the retarder heat exchanger at the rear of the crankcase is taken from the left return channel. A special water pump is provided for this purpose, so that all the coolant is also circulated to the retarder heat exchanger after the engine circuit. From the retarder, coolant is fed back into the thermostat compartment of the water pump through a separate coolant line. A separate temperature gauge is integrated into the coolant circuit. The connection for vehicle heating and coolant bleeding is through the transfer duct in the oil filter and oil cooler assembly. The standard thermostat starts to open at 83°C.

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135

Series 500<>Thermostat location

07.05.2003

The installation location of the thermostats is shown on the right of the illustration. The arrows point to the bleed tabs. These tabs must point upwards.

W 20.10-0010-06

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Thermostat location

136

Series 500<>Supercharging system and charge air ducting

07.05.2003

A completely new design has been developed for the charge air ducting in the BR 500. The charge air housing is decoupled elastically from the individual cylinder heads by means of elastomer sealing elements, which ensure noise reduction and the balancing of tolerances and different thermal expansion rates. The V6 engines have one turbocharger, and the V8 engines have two. The turbine and compressor are designed for rapid, dynamic torque build-up even at low engine speeds, and a full torque curve between 1000 rpm and 1500 rpm.

The charge air housing should be tightened to 40 Nm only!

N 09.41-2002-50

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137

Despite the two turbochargers on V8 engines, the exhaust gas is collected in a flap fitting on the left. A two-shell transverse exhaust pipe connects the right turbocharger with the flap fitting. This allows the exhaust gas guide to take the same form in vehicles with V6 and V8 engines. Depending on the installation location of the engine (high/low), or for vertical exhaust systems, different flap fittings with integral single­ piece engine brake valve are used.

N09.41-2001-50

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Supercharging system and charge air ducting

138

Previous version

n ° 9 .4 i — 2

°i i — ii

To reduce heat dissipation at the rear of the cab, two two-shell sheet metal pipes with air gap insulation are fitted between the the exhaust manifold and the turbocharger. Because of possible vibration fractures, modified pipes have been installed since March 2000. The arrow imprint must point towards the turbocharger support! A tightening torque of 50 Nm must be applied, and parts assembled free of Tension. 05/03

N14.10-2033-11

Modified version (from 03/2000) Used previously: to engine left 541 140 1203 End No. 089 130 541 140 right 1303 from engine left 541 140 1503 End No. 089 132 right 541 140 1603 The modified exhaust pipes … 1903/… 2003 fitted as engine End No. 160 569.

Replaced by: left 541 140 2103 right

541 140 2203

left

541 140 1903

right 541 140 2003 standard from

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Supercharging system and charge air ducting

139

Series 500<>Engine oil and filter change

07.05.2003

Engine oil and filter change

1 2 3 4 5 6 7

Screw cap Sealing ring Oil filter element Oil pan drain plug Oil dipstick-guide tube Engine oil suction unit Oil filler plug

N 18.00-0277-06

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Engine oil and filter change

140

O nly change the engine oil with the engine warm

h 1

Install new oil filter element (3)

2.1

Suction off the engine oil through the dipstick guide tube (5) or

Nm Oil filter cover to oil filter housing,

Nm

rn

H

Follow the manufacturer’s operating instructions for the engine oil suction unit 2.2

drain off the engine oil at the oil drain plug (4) on the oil pan.

2.2.1

Screw in the oil drain plug (5) and tighten

h

Notes on engine oil

3

Pour in the specified quantity of engine oil at the oil filler plug (7). Testing

H Fit new sealing ring to the oil drain plug. m H Plastic oil pan: the specified tightening torque must be applied.

a Danger!

4

R isk of accident due to vehicle starting off while engine is running.

Secure the vehicle to prevent it starting off automatically.

R isk of injury due to crushing or burns if components are touched during the starting procedure or while the engine is running

Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

Start engine

W atch the engine oil pressure gauge! It should indicate pressure after several seconds.

@

Do not rev the engine until oil pressure is indicated. 5 6 7

05/03

Allow the engine to run for 1 — 2 min at idle speed, once the oil pressure is indicated. Wait for about 5 minutes, then check the oil level and adjust if necessary.

H The waiting time must be observed.

Check the oil filter, the oil pan drain plug if necessary, and the long-life oil filter for leaktightness.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Engine oil and filter change

141

Engine 541.9, 542.9

® O i l filter Oil filter cover to oil filter housing

05/03

[Nm]

40

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Engine oil and filter change

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05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Engine oil and filter change

143

Series 500<>Cleaning the fuel prefilter / filter insert

1 2 3 4

Filter bowl Filter insert Sealing ring Filter housing

1. 2.

Clean the outside of the fuel prefilter if dirty Unscrew the filter bowl (1) with filter insert (2)

3.

Clean the filter bowl (1) and filter insert (2)

4.

Check the sealing ring (3) and replace if necessary

5.

Place filter insert (2) in filter bowl (1) and screw into filter housing (4)

05/03

07.05.2003

H If badly soiled or damaged, replace the filter insert H Lightly grease or oil the new sealing ring (3). |Nm|

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cleaning the fuel prefilter / filter insert

144

R isk of accident due to vehicle starting off while engine is running. R isk of injury due to crushing or burns if components are touched during the start-up procedure or when the engine is running.

Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

6.

Start the engine and bleed the fuel system.

H Let the engine run for about 1 minute.

7.

Check the prefilter for leaktightness

Danger!

The fuel system is bled automatically. If the engine remains off or will not start j bleed the fuel system manually

Engine 541.9, 542.9

Nm Fuel filter Filter bowl to fuel prefilter housing

05/03

[Nm]

10

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Cleaning the fuel prefilter / filter insert

145

Series 500<>-Fuel prefilter with water separator — replacing the filter element

1 2 3 4 5 6 7 8 9 10

07.05.2003

Filter head Filter element Separator Sealing ring Shutoff valve Bleed screw Fuel pump Sealing ring Heater plug Drain valve

N47.20-2032-05

✓

To remove

1. 2.

Place the separator under the prefilter Open the drain valve (10) and bleed screw (6)

V

Let the filter element (2) run dry

H Dispose of the water/fuel mixture in env. acceptable manner. 3. 05/03

Pull out the heater plug (9) Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>-Fuel prefilter with water separator — replacing the filter element

146

H

4.

Unscrew filter element (2)

5.

Unscrew the separator (3) from the filter element (2)

If damaged, replace the separator

6.

Clean the separator (3)

Ensure that the sealing ring groove is clean!

W M 7. 8.

To install

10.

Moisten the new sealing rings (4 and with engine oil. Screw the separator (3) with new sealing ring (8) onto the filter element (2) and finger-tighten. Screw the filter element (2) with new sealing ring (4) onto filter head (1) and finger-tighten. Close drain valve (10).

11.

Fill the prefilter with a manual fuel feed pump (7).

9.

Close the bleed screw (6). R isk of accident due to vehicle starting off while engine is running. R isk of Danger! injury due to crushing or burns if components are touched during the start-up procedure or when the engine is running. 13. Start the engine and bleed the fuel system.

Dispose of the filter element in an environmentally acceptable manner.

H

Do not use tools to tighten!

12.

14.

05/03

Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. H Let the engine run for about 1 minute. The fuel system is bled automatically.

Check the prefilter for leaktightness.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>-Fuel prefilter with water separator — replacing the filter element

147

Series 500<>Replacing the oil separator insert

07.05.2003

1 2 3 3.1

Cap Sealing ring Oil separator insert Sealing ring

W 01.20-1004-02

** M 1.

Remove cap (1) from oil separator

2.

Remove sealing ring (2) from cap (1)

05/03

|N m | H Installation: Replace sealing ring.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Replacing the oil separator insert

148

3.

Take out the oil separator insert (3).

H If an oil separator insert without sealing ring is being removed, the modified insert with sealing ring (3.1) must be installed.

4.

Install in the reverse order

Engine 541.9, 542.9

Nm C ran kcase ventilation, cylinder head cover Screw, cap to oil separator

05/03

[Nm]

6

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Replacing the oil separator insert

149

Series 500<>Replacing the fuel filter — air cleaner — coolant

1 2 3

07.05.2003

Screw cap Sealing ring Filter insert

N07.57-0207-01

/ 1. 2. W M 3. 4. 5. 05/03

To remove

Unscrewthefuel filterscrewcap(1) usingasocketwrenchbit(SW36)

H Onlyremovescrewcap(1) withfilterinsert (3)afterthefuel hasrunoutofthefilterhousing; if necessary, openthefillercap orclosethefuel cock Removescrewcap(1) offilterinsert(3)andunclipthefilterinsertbypressingat H Takecarenottoletanyforeignmatterintothefilter theside housing. Donotinanycircumstanceswipethefilterbowl. To install

Replacethesealingring(2) Insertnewfilterelement (3)inscrewcap(1) Screwonthescrewcap(1)withfilterelement (3), andtighten.

H Lightlygreasethesealingring. mEngine541, 542

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 500<>Replacing the fuel filter — air cleaner — coolant

150

6.

R isk of accident due to vehicle starting off while engine is running. R isk of injury due to crushing or burns if components are touched during the start-up procedure or when the engine is running. Start the engine and bleed the fuel system.

7.

Check the filter for leaktightness with the engine running

Danger!

Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. H L e t the engine run for about 1 minute. The fuel system is bled automatically. If the engine remains off or will not start j bleed the fuel system manually

Nm Fuel filter Cap to fuel filter housing

[Nm]

Engine 541

Engine 542

25

25

M aintaining the air cleaner Remove the air cleaner and check for dirt and damage. Clean the inside of the air cleaner housing if necessary. The air cleaner cartridge must not be cleaned with compressed air cleaning equipment. Air cleaner cartridges m ust be replaced every 3 years at least.

Engine coolant The engine coolant m ust be changed every 3 years at least.

05/03

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151

o 07.05.2003

Engines OM 904 and 906

N 01.00-0392-00

05/03

N 01.00-2138-00

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Engines OM 904 and 906

152

07.05.2003

Engine series 900

Engine model series 900 is a series of in-line engines that has been completely re-designed. Its introduction at the beginning of 1996 marked the start of final replacement of the proven 300 model series, which had been renewed and modernized again and again over a period of 25 years.

The sales designation is formed in the same way as the 300 model series:

4 -c y lin d e r e n g in e : 6 -c y lin d e r e n g in e :

OM 904 LA

Model series 900

4-cylinder in-line engine

6-cylinder in-line engine

904 LA

906 LA

VH = 4.25 / 4.8 l

VH = 6.37 / 7.2 l

OM 9 (0

OM 906 LA

A

H

Turbocharger Charge air cooler 4 = 4—cylinder in-line 6 = 6-cylinder in-line Model series 900 Diesel engine

05/03

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153

OM 904 LA — section

N 01.10-0388.50

05/03

N 01.10-0359.50

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Engine series 900

154

OM 906 LA — section

N 01.10-2004-50

05/03

N01.10-2003-50

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Engine series 900

155

07.05.2003

Series 900<>Technical features

> Outstanding power output and torque ch aracteristics over the whole rpm range > Dynamic start-off characteristics and pulling power > Attractive power/weight ratio > Low fuel consum ption > High-pressure direct injection with unit pump, pump-line-nozzle system with peak pressures up to 1 800 bar. > Electronic engine control (MR) with electronic system fixed to the engine, and extensive engine protection functions > Direct injection with centrally positioned 6-hole injection nozzle.

> Rated engine speed 2200 rpm or 2300 rpm > Low service requirements ■ long maintenance intervals ■ engine oil and fuel filter located at front for easy maintenance ■ maintenance-free belt drive > Can run on FAME / RME (rape methyl ester) or biodiesel, and engine oil changes are halved > High reliability and long runtime > Low number of parts variants — many parts are the same on both 4 and 6 cylinder engines > Rear engine power take-off ex works

> 3-valve technology with 2 intake valves and one exhaust valve > Pneumatically or hydraulically controlled constant throttle > Useful engine brake rpm well over rated rpm, up to 2700 rpm > Meets the emission legislation of EURO 3 and EUROMOT/EPA Level 2 > Turbocharger with charge air cooling > Turbocharger with wastegate valve, depending on engine model

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Technical features

156

Overview of B R 900 engines with EURO 3 certification Engine model

No. of cylinders/ layout

Output (rpm)

Torque (rpm)

Cylinder bore

Cylinder stroke

Displacement

Dimensions L x Wx H

Weight

Power/weight ratio

[kW/HP (at rpm)]

[Nm (at rpm)]

[mm]

[mm]

[l]

[mm]

[kg]

[kg/kW]

OM 904 LA

4 Cyl./in-line

90/122 (2200)

470 (1200-1600)

102

130

4.25

OM 904 LA

4 Cyl./in-line

100/136 (2200)

520 (1200-1600)

102

130

4.25

OM 904 LA

4 Cyl./in-line

110/150 (2200)

580 (1200-1600)

102

130

4.25

OM 904 LA

4 Cyl./in-line

130/177 (2200)

675 (1200-1600)

102

130

4.25

OM 906 LA

6 Cyl./in-line

170/231 (2200)

810 (1200-1600)

102

130

4.25

OM 906 LA

6 Cyl./in-line

180/245 (2200)

900 (1200-1600)

102

130

4.25

OM 906 LA

6 Cyl./in-line

205/279 (2200)

1100 (1200-1600)

102

130

4.25

OM 906 hLA

6 Cyl./horiz.

180/245 (2200)

900 (1200-1600)

102

130

4.25

OM 906 hLA

6 Cyl./horiz.

205/279 (2200)

1100 (1200-1600)

102

130

4.25

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Technical features

157

Overview of BR 900 engines with EUROM OT/EPA Level 2 certification Engine model

No. of cyl./ layout

Output (rpm)

Torque (rpm)

Cylinder bore

Cylinder stroke

Displace­ ment

Dimensions L x Wx H

Weight

Power/weight ratio

[kW/HP (at rpm)]

[Nm (at rpm)]

[mm]

[mm]

[l]

[mm]

[kg]

[kg/kW]

OM 904 LA

4 Cyl./in-line

75/102 (2200)

400 (1200-1600)

102

130

4.25

OM 904 LA

4 Cyl./in-line

90/122 (2200)

470 (1200-1600)

102

130

4.25

OM 904 LA

4 Cyl./in-line

100/136 (2200)

520 (1200-1600)

102

130

4.25

OM 904 LA

4 Cyl./in-line

110/150 (2200)

580 (1200-1600)

102

130

4.25

OM 904 LA

4 Cyl./in-line

130/177 (2200)

675 (1200-1600)

102

130

4.25

OM 906 LA

6 Cyl./in-line

150/204 (2200)

810 (1200-1600)

102

130

6.37

OM 906 LA

6 Cyl./in-line

170/231 (2200)

900 (1200-1600)

102

130

6.37

OM 906 LA

6 Cyl./in-line

180/245 (2200)

1100 (1200-1600)

102

130

6.37

OM 906 LA

6 Cyl./horiz.

190/258 (2200)

900 (1200-1600)

102

130

6.37

OM 906 LA

6 Cyl./horiz.

205/279 (2200)

1100 (1200-1600)

102

130

6.37

OM 926 LA

6 Cyl./horiz.

240/325 (2300)

1300 (1200-1500)

106

136

7.20

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158

Series 900<>Port assignments in the cylinder head gasket

07.05.2003

A Coolant B Pressure oil C Push rod/ oil return D Cylinder head bolts E Oil return Crankcase ventilation

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Port assignments in the cylinder head gasket

159

07.05.2003

Series 900<>Tightening instructions for cylinder head bolts

Cylinder head bolt test values Designation Cylinder head bolt M 16 x 2

Engine 904.9, 906.9 Shank length in new state [mm] Shank length [mm]

149 < 151

Cylinder head bolt tightening torques Designation Cylinder head bolt to crankcase

05/03

Engine 904.9, 906.9 Step 1 [Nm]

20

Step 2 [Nm]

70

Step 3 [Nm]

170

Step 4 [Nm]

280

Step 5 A

90°

Step 6 A

90°

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Tightening instructions for cylinder head bolts

160

Screw in the cylinder head bolts and, following the above tightening sequence (1 to 6), tighten to the indicated torque H

and tightening angle.

@ To ensure even contact pressure around the cylinder head gasket, follow all the tightening steps and sequence (see tightening pattern). @ If a bolt has been over-tightened when assembling, then all four bolts should be removed from the cylinder head and examined for elongation, then tightened again starting from Step 1.

So cket wrench bit

422 589 01 09 00

The cylinder head bolts do not require retightening.

Engine 904

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W 01 .30- 0005-10

Engine 906

W01 .30- 0020-04

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Tightening instructions for cylinder head bolts

161

07.05.2003

Series 900<>Valve control

The 900 model series has two intake valves and one exhaust valve per cylinder. It is therefore referred to as a «3-valve» engine. The steel camshaft (which has 5 bearings on the 4-cylinder and 7 bearings on the 6-cylinder engine) has one intake and one exhaust cam per cylinder, plus one cam for driving the unit pump. All valves are driven by the camshaft, by means of mushroom tappets and short push rods. A floating valve bridge links and actuates both intake valves. The complete valve actuation system with rocker arm bearing brackets is bolted to the cylinder head as a preassembled unit. Left view: First generation with pin-guided adjustable valve bridge, exhaust valve rocker arm with link. Right view: Next generation with floating, adjustment-free valve bridge, exhaust valve with valve cap.

N05.00-2001-50

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N05.00-2002-50

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Valve control

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GT_05_20_0015

L A S E 05/03

Bearing Exhaust valve cam Unit pump cam Intake valve cam Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Valve control

163

07.05.2003

Series 900<>Setting valve play

1 Adjusting screw 2 Locknut

Intake valve

N05.30-0372-01

Procedure for setting valve play

1

Check or set the valve play with the engine cold; at least 30 minutes after stopping the engine, even after running for a short period, so that the engine is warmed up evenly. Remove the cylinder head cover

2

Select the valve setting method

h

H Setting according to injection sequence Method 1 H Setting in two crankshaft positions Method 2

3

05/03

Install turning device (4) at the inspection hole in the timing case and turn the engine to the crankshaft position for the selected setting method.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Setting valve play

164

H

4

Check and set valve play (as indicated by arrows).

5

Remove turning device (4) and fit the cap to the inspection hole in the crankcase.

6

Fit the cylinder head covers.

The valve play test tolerance applies only for checking, not setting.

Valve test values Designation Valve play

Engine 904.9, 906.9 Intake [mm]

0.40

Exhaust [mm]

0.60

Test tolerance

[mm]

-0.10/+0.20

The valve play test tolerance applies only for ch eckin g valve play. If valve play is outside the tolerance range, the specified value m ust be set.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Setting valve play

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Valve play setting methods Firin g order 4-cylinder: 1 — 3 — 4 — 2 6-cylinder: 1 -5 — 3 — 6 — 2 — 4

A…Exhaust valve E…Intake valve X…Flyw heel side Engine OM 904 LA

Engine OM 9 0 6 LA

N01.00-0347-01

N01.00-0348-01

Method 1:

Method 2:

Set intake and exhaust valves for each cylinder, according to the injection sequence. The cylinder to be set must be at ignition TDC, the parallel cylinder at valve overlap TDC. With this method, the crankshaft must be turned four times in the 4-cylinder engine, and six times in the 6cylinder engine.

Set intake and exhaust valves in two crankshaft positions, as shown in the table. a) Adjust when cylinder 1 is at ignition TDC. with 4th or 6th cylinder at valve overlap. b) Adjust when cylinder 1 is at valve overlap and the 4th or 6th cylinder is at ignition TDC.

Engine

C ran ksh aft position

OM 904 LA Cyl. 4 valve overlap Cyl. 1 valve overlap OM 906 LA Cyl. 6 valve overlap Cyl. 1 valve overlap 05/03

C ylin d er/valves to be set 3 4

1

2

5

6

I/ E

I

E

—

—

—

—

E

I

I/ E

—

—

I/ E

I

E

I

E

—

—

E

I

E

I

I/ E

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Setting valve play

166

Series 900<>Pump-line-nozzle injection system (PLD)

07.05.2003

Location of the unit pump The injection process is performed by the newly developed pump-line-nozzle system, controlled by the Telligent®electronic engine management system. In the MR system, fuel is delivered to the injection nozzle by individual unit pumps over short, relatively rigid high-pressure injection lines, and through the pressure pipe connection screwed into the cylinder head. A unit pump fitted to the crankcase is assigned to each cylinder. The pump is driven by another timing cam on the camshaft. The camshaft therefore also has the task of driving the unit pumps, besides the traditional function of driving the intake and exhaust valves. The operating principle of the unit pump is based on the same principle as the piston pump, as in the in-line injection pumps used till now, but without control edges at the pump plunger. The quantity injected is determined individually per cylinder by solenoid valves, which control the start and end of injection.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

167

Rem oving/installing the M R/PLD unit pumps

W 0 7 .15-0082-09

1 M R /P LD unit pump 2 O-ring

05/03

3 O-ring 4 O-ring

5 Splined bolt, 65 Nm 6 Injection line

7 Engine wiring harness 8 Extractor 355 589 01 63 00

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

168

1 2 3 4 9

M R /P LD unit pump O-ring O-ring O-ring Protective sleeve 904 589 00 14 00

W 0 7 .15-1060-01

Rem oving/in stallin g 1.

Risk of explosion due to gas ignition, risk of poisoning by inhaling or absorbing fuel, or risk of injury to skin and eyes through contact with fuel.

Fire, sparks, naked flames, smoking are forbidden. Only store fuel in suitable and appropriately marked containers. Wear protective clothing if handling fuel.

2.

Remove injection line (6)

Stop up the orifices in the nozzle holder combination and M R/PLD unit pump (1).

3.

Clean the engine around the MR/PLD unit pump (1).

4.

Remove the engine wiring harness fastening strip with start/stop switch from the crankcase.

Only if removing the M R/PLD unit pump for cylinder 1 or 2

5.

Remove engine wiring harness (7) at MR unit pump (1)

To do this, loosen the screws on the solenoid valve and detach both clip fasteners.

6.

Identify the M R/PLD unit pump (1) for the cylinder concerned

Only if removing more than one or all M R/PLD unit pumps.

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169

Rem oving/in stallin g 6.

Loosen the splined bolts (5)

7. 8.

Fit the extractor (8) to MR/PLD unit pump (1) Pull out the MR/PLD unit pump (1) with the extractor (8) up to the bolt heads.

9.

Unscrew the splined bolts (5) and pull out the M R/PLD unit pump (1)

Installation: Carefully remove dirt and paint residues from the sealing surface of the M R/PLD unit pump and from the crankcase.

10.

Check the MR/PLD unit pump

Check the roller on roller tappet; if there is only slight scoring or scratching, the MR/PLD unit pump can be used again. If there is deep scoring, scratching, or sanding spots: Install a new M R/PLD unit pump The unit pump body should not be disassembled.

05/03

For reasons of safety, the splined bolts should be unscrewed by only about 4 to 5 mm; the MR/PLD unit pump is under spring load. Extractor: 355 589 01 63 00 If stuck, the M R/PLD unit pump should not be pressed out at the solenoid valve or at the housing flange. Installation: Lightly oil the unit pump body, O-ring surfaces (2, 3), and hole in the crankcase with engine oil. Insert the unit pump in the crankcase using the mounting pins. Before pressing in the MR/PLD, check that the fuel feed pipe and transfer hole are aligned with each other. Carefully press in the MR/PLD unit pump by hand, to a depth of about 4 mm. If the unit pump cam on the camshaft is at the top, turn the engine by about a half-revolution (in direction of rotation). Insert the MR/PLD unit pump into the crankcase with the splined bolts, tightening slowly and alternating between bolts. Tighten the splined bolts (……..Nm)

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

170

11.

12.

Rem oving/in stallin g

RemoveO-rings(2, 3, 4)fromMR/PLDunitpump(1)

Install inthereverseorder

Cleantheradial grooveintheunitpumpbody. Coatthenew o-ringswithengineoil. Pushprotectivesleeve(9, 90458900 1400)over theunitpumpbody. FirstslideO-ring(2)overprotectivesleeve(9)into thegroove, thenO-ring(3). AvoidtwistingtheO-rings(2, 3, 4)whenfitting intothegrooves. Installation:

904 589 00 14 00

Theassemblingpins(two)areshop-madefromroundmaterial (St37), tothespecifieddimensions. A=M10x1.5 B=10.0mm±0.5mm C=80.0mm±1.0mm D=10.6mm±0.1 mm

<

‘///I

o

B

W58.50-1005-01

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171

Unit pump classification

TheBR457, 500and900unitpumpsareclassifiedatmanufacture. W heneachpumpisinstalledintheengineontheassemblylineatMannheim, itsclassificationisregisteredandstoredintheMRelectronicsystem. Toensuresmoothenginerunning, theclassificationvaluesaretakeninto accountwhendistributingthefuel quantity(injectiontiming). Toensurethatsmoothenginerunningcontinuesafterunitpumpsarereplaced ormodifiedfordiagnosticpurposes, theunitpumpclassificationmustbe assignedtothecylinder. An input error m ay lead to rough engine running and overloading of individual cylinders. Then reset the individual cylinder torque control to «0».

AXO R

MR

Replace the unit pump Cylinder

Code

1

C y lin d e r 1

X-XXX-XXX -X X -X X X X X

2

C y lin d e r 2

X-XXX-XXX -X X -X X X X X

3

C y lin d e r 3

X-XXX-XXX -X X -X X X X X

4

C y lin d e r 4

X-XXX-XXX -X X -X X X X X

5

C y lin d e r 5

X-XXX-XXX -X X -X X X X X

6

C y lin d e r 6

X-XXX-XXX -X X -X X X X X

Note: The user must read off the unit pump number on the unit pump and enter it for the corresponding cylinder. Only enter the number for unit pumps being replaced.

Press F3 to confirm.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

172

Theclassificationiscodedasa 14-digit number(C) ontheunitpumpmodel plate. Thecodeisentered throughthe»ReplaceUnitPump» menuinDAS. A028 074 60 02-

A= MBnumber B= Certificationnumber C= Unitpumpnumber(classification) D= Barcode E,G,H= Manufacturerinformation F= Manufacturerbarcode

SE 9401

N07.02-2028-01

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

173

Sealing the intermediate plate of the unit pump — BR 900

1 1.1 1.2 2 3 4 5 6 7 8 9 10

Pump body Anchor plate Crosspiece Seal Intermediate plate Solenoid Model plate Screw Stop plate O-ring O-ring O-ring

11

^ S le e v e

12

^ S c re w d riv e r bit

W 0 7 .15-1061-06

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

174

** ® 1. 2. 3. 4.

5. 6. 7. 8. 9. 10. 11. 12.

05/03

To remove

Utmostcleanlinessshouldbeensuredwheneverworkingontheunitpumps. RemovetheMR/PLDunitpump RemoveO-rings(8, 9, 10))fromunitpump(1) Pushthesleeve(11) ontounitpump(1) CleantheupperpartoftheMR/PLDunitpump.

@ Firstcleanthebottompartofthepumpbody(1). @ Sothatdirtwill notget intotheorifices. St @ Carefullyremovepaintresiduesonthesealingsurfacesof theMR/PLDunitpump. H Thehighpressureorificemust beclosedoff. Nodirtor cleaningagentshouldbeallowedtopenetrateintothepump body(1). Identifytheintermediateplate(3) (arrowA)forthepumpbody(1) andplacethe @ Useascriberortouch-uppencil, neverastampingtool. MR/PLDunitpumpatstopplate(7). Loosenthescrews (6), andremovesolenoid(4)togetherwithintermediateplate H Firstremovepaintresiduesfromthescrewheadswitha (3)andmodel plate(5). scriber(arrowB). St

Removeintermediateplate(3)andmodel plate(5)fromsolenoid(4). H Cleanthesealingsurfaceofthesolenoid. Takeoutseal (2)andcleanintermediateplate(3) @ Donotdamagethesealingsurfaces. Identifythecrosspiece(1.2) andanchorplate(1.1) forpumpbody(1) (arrowC). @ Useatouch-uppencil, neverascriberorstampingtool. Thecrosspieceshouldnotbemovedorturned. Applycleaningspraytothesealingsurfacesof pumpbody(1), crosspiece(1.2) @ Cleanthepartscarefully. andanchorplate(1.1). H Donotremovepaintresiduesfromthepumpbody(1), thesewill beneededforlocatingtheintermediateplate(3). Takeoffstopplate(7) Cleanthemodel plate(5) @ Removepaintresiduesaroundthecontactsurfaceofthe screwheads. Donotremovetheprotectivefoil onthemodel plate. Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

175

w M 13. 14. 15.

To install

Placenewstopplate(7) underpumpbody(1). Insertnewseals (2)inintermediateplate(3). Placeintermediateplate(3)onpumpbody(1).

H Protectthesealswithgrease @ Payattentiontotheidentificationmarksonthecrosspiece (1.2) andanchorplate(1.1) forpumpbody(1). Thecutouts (arrowsD)attheopeningintheintermediateplatemustpoint towardsthecrosspiece(1, 2). H Thepaintresiduesareusedtolocateintermediateplate(3) onpumpbody(1).

16.

Placesolenoid(4)onintermediateplate(3).

17.

Assemblethemodel plate(5), solenoid(4), intermediateplate(3), pumpbody(1) HH Tightenthescrewscrosswise. andstopplate(7), andfastenwithnewscrews (6). S904 589021 000 S001 589021 100 Takeoffsleeve(11) S904 589031 400 Install MR/PLDunitpumps H FitO-rings(8, 9and10), followingtheinstallation specification.

18. 19.

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

176

Engine 904.9, 906.9

Nm Diesel injection system with unit pum ps

Screw,solenoidvalvetoMR/PLDunitpump

05/03

Step 1 [Nm] Step2[Nm]

2 4

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

177

Injection nozzle — BR 900

Theinjectionnozzledoes nothavealeakoil hole. Thiscauses pressuretobuildupinthespringchamber. Thispressureacts likeahydraulicspring, andtakesonthefunctionofasecondcoil spring. Theinjectioncharacteristicsaresimilartothosewitha2-springretainer. Thespringchamberpressure dependsonloadandrpm,andcanreachamaximumof 180bar. Thespringchamberpressurehaslittle effectat lowenginespeedsandloads, buthasastrongeffectat highenginesspeedsandloads. Thisgivesaninjectionnozzleopeningpressurevaryingfromabout 250to500bar. Note:

thisnozzlecannotbecheckedoradjustedbyBoschDiesel services.

N07.03-2018-03

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178

Injection nozzle OM 906 LA

FortheintroductionoftheOM906LAengines, thenewinjectionnozzlewithsealingsleevewas usedforthermal reasons. Ifaninjectionnozzleisremovedduringrepairs, thesealingsleevemustalways bereplacedaswell. Aspecial tool mustalways beusedtofitthesealingsleeve. Pressin g the sealing sleeve onto the injection nozzle

1 Nozzleholdercombination 2 Sealingsleeve 3.1 Mountingsocket (fornozzleholder head) 3.2 Assemblysleeve(forsealingsleeve)

906 589 00 63 00

05/03

W07.03-1003-11

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

179

Location of pressure pipe connection, nozzle holder combination, and nozzle protective sleeve

Thepressurepipewithintegral pin-typefilterformstheconnectionfromthehigh-pressureinjection linetothevertical, centrallypositionednozzleholdercombinationwiththeinjectionnozzle. Thenozzleholdercombinationisplacedinsideaprotectivesleeveandisattachedtothecylinderhead bymeansofaclampingclaw.Thecombustiongasseal consistsofacopperringorsealingsleeve. Theprotectivesleeveitself isprotectedfromthecoolant byanO-ring, andonthepressuresidebythe threadandthecontactsurface.

N07.03-2038-01

1 7 8 10 11

05/03

Nozzle holder combination O-ring Copper sealing ring Pressure pipe connection Pressure screw

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

180

1 2 3 4 5

Nozzle holder combination Adapter 904 589 00 63 00 Extractor 355 589 01 63 00 Screw (up to End No. 0 4 6 8 9 2 ), 30 Nm Spherical w asher (up to End No.046892)

05/03

6 7 8 9 10

Spherical collar bolt (from End No. 046893), 35 Nm Retaining clip O-ring Sealing ring (906 engine up to End No. 056812) Sealing sleeve (906 engine from End No. 056813)

O-ring Pressure pipe connection Pressure screw, 40 Nm Injection line Constant throttle cap

W 07.03-1008-09

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

181

To remove

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

05/03

Removethecylinderheadcover. Riskofexplosionduetogasignition, riskof poisoningbyinhalingor Fire, sparks, nakedflames, smokingareforbidden. Onlystorefuel in absorbingfuel, orriskof injurytoskinandeyesthroughcontactwithfuel. suitableandappropriatelymarkedcontainers. Wearprotectiveclothingif handlingfuel. Removeinjectionline(14) Removepressurepipeconnection(12) Removeretainingclip(7) Fittheadapter(2)andextractor(3)totheinsidethread(M8)of nozzle Adapter: 904589006300 holdercombination(1) Extractor: 355 58901 6300 Takeout nozzleholdercombination(1) Thenozzleholdercombinationshouldnotbedisassembled. Ifwornor faulty, install newnozzleholdercombination. Removetheadapter(2)andextractor(3)fromnozzleholdercombination (1) Takeoutsealingring(9). All 904enginesand906engineuptoEndNo. 056812 Notethethicknessof theremovedsealingring(givesnozzleprojectionat thecylinderheadseparatingsurface). Pull sealingsleeve(10) outof nozzleholder (1) 906enginefromEndNo. 056813 Ifsealingsleeve(10) remainsstuck: pull sealingsleeve(10) outofcylinderhead Extractingtool 906589026300 Adapter904589006300 Extractor355 58901 6300

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

182

w M 11. 12. 13. 14.

15. 16. 17. 18. 19. 20.

05/03

To install

ReplaceO-ring(8)onnozzleholdercombination(1) Placesealingring(9)atnozzleholdercombination(1)

CoattheO-ringwithslidingcompound(ATEgrease). Onall 904enginesand906engineuptoEndNo. 056812, replacethe sealingring. Notetheinstallationlocationandthicknessofthesealingring: thesmaller ringsurfaceshouldpointtowardsthenozzleholdercombination. Pressnewsealingsleeve(10) ontonozzleholdercombination(1) 906enginefromEndNo. 056813 Assemblytool: 906589006300 Install nozzleholdercombination(1) Notetheinstallationlocationofthenozzleholdercombinationatthe pressurepipeconnection. Twistthenozzleholdercombinationwith retainingclip(7)intothecylinderheaduntil thepress-inball (arrowed) in theretainingclipisalignedwiththefixingintheconstantthrottlecap (15). Tightentheretainingclip(7)andspherical washer(5)withthebolt(4) UptoengineEndNo. 046892, hexagonsocket head, 30Nm FromengineEndNo. 046893, 12-pointheadboltwithspherical collar, Tightentheretainingclip(7)andspherical collarbolt(6) 35 Nm. ReplaceO-ring(11) onpressurepipeconnection(12) CoattheO-ringwithslidingcompound. Install thepressurepipeconnection(12) andtightenthepressurescrew, Thepress-inball (arrowed) must beengagedinthegroove(arrowed) in 40Nm. thecylinderhead. Install theinjectionline(14) Fitthecylinderheadcover

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

183

Special tools

QpiJ 355_589_01_63_00

904_589_00_63_00

906_589_00_63_00

Rem arks:

5.) Extractingtool 906589026300isnow usuallysuppliedtogetherwiththeextension. 6.) FromApril 2003, forneworders underthe existingnumber, special tool 9065890063 00issuppliedwithmodificationtoPart 1. Toextendexistingtools, themodifiedPart 1 canalsobeorderedseparatelyunder number906589006301. 906_589_02_63_00

05/03

Extracting tool extension

906_589_02_63_01

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pump-line-nozzle injection system (PLD)

184

Series 900<>Crankcase

07.05.2003

All enginesarebasedontheparticularlystable, noise-optimizedcrankcase, whichismadeofahigh-carbon/cast ironalloy. Design features:

• • • • • • • •

Boththe4andthe6-cylinderenginehaveonlyonevariant. Compactdesignthroughintegrationoftheoil cooler, theunitpumps, and thecoolant, fuel andoil ports. Highlyrigid, highcarbon/cast ironalloy. Rigidsidewalls, extendingwell pastthecenterofthecrankshaft. Thismeansthattheseparatingsurfaceoftheoil panislocatedlowerthan thelevel ofthecrankshaftcenter. Thefrontenginemountislocatedatcylinder2. Induction-hardenedcylindercontactsurfaces. Drycylinderlinerscanbeinserted. Ontheleftontheflywheel side, anassemblinglugisprovidedforattaching thecompressorwithpowersteeringpump. W 01.40-1017-11

05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Crankcase

185

Induction-hardened cylinder contact surfaces and liners

N01.40-2033-11

Cylindercontact surfaceswithinduction-hardenedstripsareprovidedatthe upperpistonreturnpoint, aroundtherings, toincreaseenginelife.

05/03

N01.40-2032-11

Cylinderlinerscanbeinsertedforrepairs. Drillingsareprovidedinthe crankcaseforthis purpose.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Crankcase

186

Coolant drain plug

Acoolantdrainplug(1) isfittedtothecrankcase, toalloweasierdrainingof thecoolantcircuit. Thescrewplug(2)inthemainengineoil ductismountedwithLoctite221.

N01.40-2051-11

Engine b lock heater connection

Fromabout03/99, anadditional hole0 60mmisprovidedattherightrear(arrowed)ofthe crankcase. Thisholeisfittedwithacap(1)asstandard. Thecapisremovedifinstallingan engineblockheater(special equipment) (2).

N01.40-2058-01

05/03

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187

Series 900<>0lspritzdusen — Unterschiede

07.05.2003

W 18.00-0002-05

Version1: Screw-inoil spraynozzle

05/03

W 18.00-1004-05

Version2: Press-inoil spraynozzle Thecrankcasemust beremovedtoinstall/removetheoil spraynozzle. To ensurethecorrectspraydirectionforthepistoncooling, thepress-inoil spraynozzles(1) mustonlyberemoved/installedwiththecorrect special tools.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>0lspritzdusen — Unterschiede

188

Series 900<>Pistons and piston rings

07.05.2003

Pistons and piston rings are among the most highly stressed engine components. Pistons are therefore constructed of high-temperature aluminum alloy. The piston top land and stem are graphite-coated to increase running-in and limp-home capability. There is a cast-in, reinforced ring groove for the first piston ring. The piston pin support is trapezoidal in shape, to increase the pressure-load surfaces on the piston and connecting rod.

Features of the piston rings: Groove 1: Compression ring Cast-iron keystone ring with plasma spray layer of chromeceramic, spherical-lapped. Groove 2: Compression ring with oil-scraper action. Chrome-plated taper-faced ring with internal angle underneath. Groove 3: Oil scraper ring Roof bevel ring with chrome-plated, lapped lands and garter springs.

N 03.10-2001-50

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Pistons and piston rings

189

Series 900<>Connecting rod

07.05.2003

Aparticularfeatureofthemanufacturingtechnologyusedtoproducethe forgedsteel connectingrodisthe’cracking’ process usedtoseparatetherod fromthebearingcap. W iththisprocess, theconnectingrod(producedinonepieceuptonow)is splitatthebigconnectingrodeyeatanexactlypre-determinedfractureline. Theseparatedpartsarethenboltedtogethertoformaprecise, exact-fitting attachmentforthebearing. Note:

Becauseofthe’cracked’ surfacestructure, special careandcleanlinessis requiredwhenperformingrepairs. N 03.10-2025-10

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Series 900<>Pistons and connecting rod — modifications

07.05.2003

Fromabout 11/99, becauseofthenewpistonpinsforEuro2engines(2), with42.0mmdiameter (previously40.0mm)and80.0mmlength(previously78.0mm), thepistons(1) andconnectingrods(3) hadtobemodifiedalso. AsstandardforEuro3engineswith0 102 mmcylinders Pistonsof0 102mmwithcombustionchamberrecessdiameterof 73.08mmanddepthof 13.57 mm, givingachamberrecessvolumeof46.96± 0.6cm3 (Euro2pistonsof0 102 mmwithcombustionchamberrecessdiameterof75.0mmanddepthof 13.0mm,givingachamberrecessvolumeof 50.36± 0.6cm3) AsstandardforEuro2engineswith0 106mmcylinders Pistonsof0 106mm(Euro2)withcombustionchamberrecessdiameterof 78.0mmanddepthof 13.4mm,givingachamberrecessvolumeof 58.25± 0.6cm3)

N 03.10-2047-03

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Series 900<>Engine oil circuit

07.05.2003

Shownon904.9engine 1 2 2.1 2.2 3 4 5 6 7 8 9 10 11 12 13 14

Oil pan Oil pump Pressure limiting valve Oil pump strainer with oil intake tube O il/w ater heat exchanger Oil filter housing Main oil duct Oil pressure line to turbocharger Oil spray nozzle Main con-rod bearing on crankshaft Cam shaft bearing Oil rear cro ss duct Oil duct to unit pumps Oil duct to cylinder head Rocker arm spindle Rocker arm with oil hole

W 18.00-1005-06

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Enginelubricationreducesthemechanical wearonmovingpartsandmakestheirworkeasier. Atthesametime, thepartsarecooledandimpactsabsorbed. The m ost im portant com ponents of the engine lubrication / cooling system are:

Oil pan Oil pumpwithpressurelimitingvalve Oil/waterheatexchanger Oilfilterhousingwithoil filter, drainvalve, filterbypassvalve, andoil retentionvalve(returnflowcheckvalve) Oilspraynozzles Mainoil duct, oil crossduct. oil ducts(cylinderheadunitpumps)withoil lines Rockerarmspindle Oil pump

Theoil pumpconsistsofageartypepumpandislocatedinthefrontendcover. Itisdrivenbythecrankshaft. Itdeliverstheengineoil fromtheoil panthrough anoil ducttotheoil/waterheatexchanger. Pressure relief valve

Thepressurereliefvalveislocatedundertheoil pumpandmaintainstheoil pressureat3to4bar. Iftoomuchoil isdeliveredat highenginespeeds, the pressurereliefvalveopensandallowstheengineoil toflowdirectlyfromtheoil pumpbacktotheoil pan. O il/w ater heat exchanger

Theoil/waterheatexchangerislocatedontherightsideofthecrankcase. Theengineoil flowsthroughtheplates (8elements) intheoil/waterheatexchanger, andthesearewashedaroundbytheenginecoolant. Sincetheengine coolantisataconsiderablylowertemperaturethantheengineoil, thecoolantabsorbstheheatfromtheengineoil andcoolsitdowntoengineoperating temperature. Duringcoldstarts, theengineoil isheatedbythesurroundingcoolantthroughtheoil/waterheatexchanger.

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Oil ducts and oil lines

Oilductsareintegratedintothecrankcaseand cylinderhead. Theoil pressurelinestothe turbochargerandpowertake-off (special equipment, fittedtothecrankcase) arelocated externally. Theotheroil ductstothecrankshaft bearingsand oil spraynozzlesaresuppliedwithengineoil throughthemainoil duct, locatedontheright sideofthecrankcase. Otheroil ducts leadinthe crankcasefromtheindividual crankshaft bearings andtothecamshaft bearings. Theconnectingrod bearingissuppliedwithengineoil throughoil ductsintegratedintothecrankshaft. Engineoil isfedfromthemainoil ducttothe compressorandcylinderheadthroughanoil duct systemintherearwall ofthecrankcase. Afurther longitudinal oil ductontheleftsideofthe crankcasesuppliesengineoil totheMR/PLDunit pumps. Engineoil isdeliveredtothelast rocker armbearingbracketthroughholesinthecylinder headgasketandtheoil ductintherearofthe cylinderhead. Fromtherockerarmspindle bearingbracket, oil thenpassestotherockerarm spindleandall therockerarms.

N 18.00-2004-50

Itthenpassesthroughtheoil holesintherockerarmsandalsosuppliesthevalveassembly. Theoil ductsinthecrankcasearepartlyclosedwithscrewplugsor balls. Theoil thenflows backtotheoil panthroughoil returnholesinthecylinderheadandcrankcase. 05/03

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Oil filter

Theoilfilterhousingisfittedtotherightfrontofthecrankcase. Itcontainsanoilfilterinsert, madeof paper. Theoil filterinsertisclippedintotheoil filtercover. Theoil filterinsertisreplacedfromthetop. W henthefiltercoverisunscrewed, engineoil inthefilterhousingflowsthroughthedrainvalvebackinto theoil pan. Drain valve

Thedrainvalveislocatedintheoil filterhousingunderthefilterinsert, andopenswhenthefiltercoveris unscrewed. Thisensuresacleanerfilterchangeandlessenvironmental pollutionbyreducingtheamount of residual oil intheoldfilter. Filter bypass valve (open ingpressure 1. 8-2. 6bar) Thefilterbypassvalveislocatedinthetopdome(filterhousing)oftheoilfilterinsert. Thenormal position ofthefilterbypassvalveisclosed. Iftheoil filterinsertisclogged, thepressureincreaseinthefilter housingopensthefilterbypassvalve. Thisensuresthattheengineislubricated, althoughtheengineoil passingthroughthebypassvalveisunfiltered. Oil retention valve (return flow ch eck valve)

Theoil retentionvalve(openingpressure0. 03-0. 07bar) isplacedintheoil filterhousingandis intendedtopreventtheengineoil intheoil ductsfromflowingbackintotheoil panwhentheengineis stopped. Theoil ductsarethereforealwaysfilledwithoil. W hentheengineisrestarted, thisensuresthat componentsalways receiveoptimal lubricationimmediately. Oil sp ray nozzles

Theoil spraynozzlesarelocatedinthecrankcase. Thereisoneoil spraynozzlepercylinder. Theoil spray nozzlessprayengineoil continuouslyunderthepistoncrownstocool themdown. Oilissuppliedtotheoil spraynozzlesthroughthemainoil duct. N 18.20-2021-03

Com bination oil tem perature se n so r/ pressure sensor

Theoil temperaturesensorandoil pressuresensorarelocatedonsideoftheoil filterhousing.

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Series 900<>Removing/installing the oil pan

1 2 3 4 5 6 7

07.05.2003

Oil filler line Seal Oil pan Bolt Sealing ring Oil drain plug N oise encapsulation

W 01.45-0004-06

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Procedure for rem oval/installation of the oil pan

1 2 3

Suctionofftheengine Removeoil fillerline(1)fromtheoil pan Removeoil pan(3)

4 5 6

Install inthereverseorder Checktheoil level withtheoil dipstick R isk of accident duetovehiclestartingoffw hileengineisrunning. R isk of injury duetocrushingorburn sifcomponentsaretouchedduringthestart-up procedureorwhentheengineisrunning Starttheengineandwatchtheoil pressuredisplayatidlespeed

7

Stoptheengineandcheckforleaktightness

Danger!

05/03

H Installation: Cleantheoil panandseparatingsurfaceon thecrankcase. Replacethesealingring(2); notetheinstallationlocation. @ OM904only: FromengineEndNo. 004313 toEndNo. 004449, oneboltisshortened; notethelocationat leftrearof theoil pan(compressorside). @ Oilpanbolttocrankcase H Installation: Replacethesealingring(5) @ Oildrainplug Securethevehicletopreventitstartingoffautomatically. Wearclosedandsnug-fittingworkclothes. Donottouchhotorrotatingparts. @ Starttheenginewiththestarterfor90secondsmaximum. Repeatthestartingprocedureafterwaitingabout 2minutes. Donotrevtheengineuntil oil pressureisindicated. H Theoil pressuregaugemustshowtheoil pressureafter about 10seconds.

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Engine oil pressure test values Designation

Engineoil pressureat

Engine 904.9, 906.9

Idlespeed[bar] Maximumrpm[bar]

>0.5 >2.5

Oil pan bolt tightening torques Engine 904.9, 906.9

Nm Oil pan

Oilpanbolttocrankcase Drainplugonoil pan

05/03

[Nm] M20x1.5 [Nm] M26x1.5 [Nm]

25 65 85

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Series 900<>Fuel system

07.05.2003

Cam shaft

Fuel pumpdrive

N05.20-2013-10

Arrowindicatesoil holefor lubricationofthefuel pumpdrive

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Fuel prefilter with heated water separator

Incountrieswherethefuel isconsideredtobeheavilycontaminatedandto havehighwatercontent, anadditional fuel filterwithintegratedwater separator(includingmanual feedpump)ishighly recom m ended . V eh icles that are run in countries of Eastern Europe, or filled with fuel from those countries, m ust be fitted with a prefilter.

Advantages to the custom er:

• Increaseddurabilityoftheinjectionsystem • Longmaintenanceintervalsdespitedifficultoperatingconditions • Greatereconomythroughshortervehicledowntimes. W47.20-1006-11

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Location of the fuel filter bowl

N47.20-2034-02

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W 47.20-0003-06

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Fuel system — real-life representation

1 2 3 5 6 7 8 9 10 12 13 14 15 16 17 A B C D

Fuel feed pump (KFP) Fuel filter (KF) Fuel feed duct in crankcase Nozzle holder combination Pressure pipe connection Injection line Overflow valve (4.5 bar) Fuel return flow duct in crankcase Unit pump (Y6 to Y11) Fuel prefilter Fuel line (prefilter — feed pump), suction side Fuel feed from tank Fuel return to tank Fuel feed to flame starting system Fuel return flow duct from cylinder head Fuel feed/suction side Fuel return/ leak fuel Fuel feed/pressure side Fuel high pressure

N07.00-2027-06

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Fuel system — sym bolic representation

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Fuel c irc u it s c h e m a tic d ia g ra m

1 1.1 1.2 2 2.1 2.2 3.1 5 8 8.1 10 12 12.1 14.1 15.1 17 171 18. 1 18.2

Fuel feed pump (KFP) Pressure limiting valve in KFP pump (9.2 bar) C h e ck valve in KFP pump (0.2 bar) Fuel filter (KF) Fuel drain valve Constant vent in fuel filter (KF) Bypass from fuel feed duct to fuel return duct Nozzle holder combination Overflow valve (4.5 bar) Constant vent (0.5 mm) PLD unit pumps (Y6 to Y11) Fuel prefilter (KVF) C h e ck valve in prefilter (KVF) Plug-on valve in fuel feed (locked open) Plug-on valve in fuel return (locked open) Fuel tank Air intake valve Throttte (° . 5 mm) in flame sta rt fuel !ine Throttle (threaded orifice) in flame start fuel line

B10 R3 Y5

Fuel temperature sensor Flame start glow plugs Solenoid valve

D E

Fuel high pressure side (after PLD unit pumps) Fuel return (fuel drain)

——————

Fuel ducts in crankcase Fuel lines

G H

Pressure gauge testing Fuel return quantity testing

I

Fuel pressure after fuel filter Idle speed: > 4.3 bar Cutoff speed: 4.0 — 6.5 bar Fuel return quantity at nozzle holder combination Test period: 5 min no fuel Fuel return quantity at fuel filter bowl outlet Idle and cutoff speed: < 0.3 l/m in Fuel return quantity at overflow valve Idle speed: 0.9 -1.7 l/m in

T e s t points, in s p e c tio n d a ta

II

III

IV

V Fuel sy s te m

A B C

05/03

Fuel feed (intake/vacuum side) Fuel return (leak fuel) Fuel feed (pressure side)

Cutoff speed: 2.7 — 7.5 l/m in Fuel intake pressure before fuel pump Idle speed: -0.09 to -0.12 bar Cutoff speed: -0 .4 to -0.5 bar Low pressure-fuel system leaktightness Test pressure: 5.0 bar Test period: 5 min Pressure drop: < 0.25 bar

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Fuel system

205

Checking the fuel system

In w hat circu m stances m ust the fuel pressure be checked?

Poorstartup, poorperformance W hat can cause the fuel pressure to be too low?

Dirtyprefilter, dirtyfuel filter, faultyoverflowvalve, fuel systemisdrawinginair, Kinkinfeedlinefromtank, intakelineatfuel tanksensor, checkvalveatprefilterinlet, leakinfilterbowlatthereturnflow,faultyfeedpump W hat can cause the fuel pressure to be too high?

Faultyoverflowvalve, kinkinreturnflowline, checkvalveat returnlineconnectiontofilterbowl, fuel tanksensorclogged W hat other operations should be carried out?

Checkthefuel systematandintheengineforleaktightness, checkthefuel intakepressure, measurethefuel returnquantity, measurefuel returnquantityat nozzleholdercombination.

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Checking the fuel pressure

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Checking the fuel intake pressure

W 0 7 .15-1008-06

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Measuring fuel return quantity at the nozzle holder combination

N 0 7 .15-2020-06

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Measuring the fuel return quantity

W 0 7 .15-1012-09

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Ch ecking the engine fuel circuit for leaktightness

Thefuel systemshouldonlybepressurizedto5bar, toavoiddamagetoanyfuel coolerinstalledintheelectronicsystem. 05/03

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Fuel system

211

Series 900<>Supercharging system and charge air ducting

07.05.2003

Thechargeairisdrawnfromtheaircleaner throughthecompressorturbinewheel ofthe turbocharger, throughtheon-boardchargeair cooler, thenfedintothecombustionchamber. Thechargeairisre-cooledtobelow50°C. Thehotexhaustgases leavethecombustion chamberthroughtheexhaustmanifoldandpass intotheturbocharger. Aheatshieldovertheturbochargerpreventsheat dissipationintotheenginecompartment.

N01.00-0497-50

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212

Theturbochargerissurge-proofandisdesigned forrapid, dynamicpressurebuild-upevenat low enginespeeds. Thisensures promptstart-off characteristicsandacceleration. Inenginesoftheupperpowercategory, this functionisperformedbythewastegatevalve. In themediumandlowerenginespeedrange, the turbochargercanbedesignedforhighboost pressureandincreasedtorque. Atthehigher enginespeeds, theboost pressureisthenlimited bytheopeningofthevalve, whichcauses partof theexhaustflowtobypasstheturbochargerand passdirectlyintotheexhaustsystem.

W 09.40-0012-06

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213

N 09.41-2011-82

Chargeaircircuitwithoutwastegatevalve 05/03

N 09.00-2009-00

Chargeaircircuitwithwastegatevalve

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Supercharging system and charge air ducting

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Series 900<>Removing/installing the coolant thermostatic control

07.05.2003

W 20.10-0015-12

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216

EIIE

Rem o ving/in stallin g

Danger!

1 ® 2

toskinandeyesduetoscalding, as hotcoolantmayspurtout. ifcoolant isswallowed.

R isk of injury R isk of poisoning

Drainthecoolant Notesoncoolant Removethecoolant line(4)

Onlyopenthecoolingsystematcoolanttemperatures under 90°C. Openthecapslowlyandreleasethepressure. Donot storethecoolantindrinkcontainers. Wearprotectivegloves, protectiveclothingandsafetyglasses. H Collecttheescapingcoolant |Nm|

3

Removethecoolantthermostaticcontrol (4)

4

Install inthereverseorder

05/03

H Installation: ReplacetheO-ring(3). Notetheinstallationlocationofthecoolantthermostatic control. Theblowhole(arrowed) mustalwayspointupwards.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Rem oving/installing the coolant thermostatic control

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Series 900<>Engine oil and filter change

1 2 3 4 5 6 7

07.05.2003

Cap (oil replenishment) Screw cap Sealing ring Oil filter Oil pan drain plug Oil dipstick-guide tube Oil dipstick

N 18.00-0385-06

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Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Engine oil and filter change

218

H 1. 2. 1

O nly change the engine oil with the engine warm

2.2 2.2.1

Drainofftheengineoil attheoil drainplug(5)ontheoil pan. Screwintheoil drainplug(5)andtighten

Install newoil filterelement(4) Suctionoffengineoil throughthedipstickguidetube(6)

E H Followthemanufacturer’soperatinginstructionsforthe engineoil suctionunit. H Removethebottompartsofthenoiseencapsulation H Fitnewsealingringtothedrainplug |Nm|

H 3. Danger!

4. 5. 6. 7.

05/03

Notesonengineoil Pourinthespecifiedquantityofengineoil atthefillerhole(1) R isk of accident duetovehiclestartingoffw hileengineisrunning. R isk of Securethevehicletopreventitstartingoffautomatically. injury duetocrushingorburn sifcomponentsaretouchedduringthestart-up Wearclosedandsnug-fittingworkclothes. Donottouchhotorrotatingparts. procedureorwhentheengineisrunning Startengine W atch the engine oil pressure gauge! Itm ustindicatethe pressureafterseveral seconds @ Do not rev the engine until oil pressureisindicated. Stoptheengineafteroil pressureisindicated. W aitatleast5minutes, thenchecktheoil level andadjust ifnecessary H Thewaitingtimemust beobserved. Thewaitingtimemust beobserved.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Engine oil and filter change

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N 18.20-0252-01

1.

3.

Unscrewtheoil filterscrewcap(1) usingasocketwrenchbit(SW36). Allowthe oil torunoutofthefilterbowl. Removescrewcap(1)withoil filterinsert(3), andunclipfilterinsert(3) by H Takecarenottoletanyforeignmatterintothefilterbowl. pressingattheside. Donotinanycircumstanceswipethefilterbowl. Replacethesealingring(2) H Lightlygreasethesealingring.

4. 5.

Insertnewoil filterelement(3)inscrewcap(1) Screwonthescrewcap(1)withoil filterelement(3), andtighten.

2.

Nm Engine 904.9, 906.9

Nm Oil filter

Oilfiltercovertooil filterhousing 05/03

[Nm]

25

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Engine oil and filter change

220

Series 900<>Cleaning the fuel prefilter — filter insert

07.05.2003

1 2 3 4

Screw cap Sealing ring Filter insert Filter housing

N07.57-0224-01

1. 2. 3. 4. 5. 6.

05/03

Openthecaponthefuel tank; allowpressuretoescape, orclosethefuel cock. Cleantheoutsideofthefuel prefilterifdirty Unscrewscrewcap(1)withfilterinsert(3), andtakeoutoffilterbowl(4). H Takecarenottoletanyforeignmatterintothefilterbowl. Donotinanycircumstanceswipethefilterbowl. Cleanthescrewcap(1)andfilterinsert(3) H Ifbadlysoiledordamaged, replacefilterinsert(3) Checkthesealingring(2)andreplaceifnecessary H Lightlygreaseoroil thenewsealingring(3). Screwonthescrewcap(1)withfilterelement (3), andtighten. |Nm|

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Cleaning the fuel prefilter — filter insert

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Danger!

6. 7.

Wearclosedandsnug-fittingworkclothes. duetovehiclestartingoffwhileengineisrunning. R isk of duetocrushingorburnsifcomponentsaretouchedduringthestart-up Donottouchhotorrotatingparts. procedureorwhentheengineisrunning. Starttheengineandbleedthefuel system. H Lettheenginerunforabout 1 minute. Thefuel systemis bledautomatically. Checktheprefilterforleaktightness R isk of accident injury

Engine 904.9, 906.9

m Fuel filter

Captofuel prefilterhousing

05/03

[Nm]

25

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Cleaning the fuel prefilter — filter insert

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Series 900<>Fuel prefilter with water separator — replacing the filter element

1 2 3 4 5 6 7 8 9 10

✓ 1. 2.

V

05/03

07.05.2003

Filter head Filter element Separator Sealing ring Shutoff valve Bleed screw Fuel pump Sealing ring Heater plug Drain valve

To remove

Placetheseparatorundertheprefilter Openthedrainvalve(10) andbleedscrew(6)

Letthefilterelement (2) rundry H Disposeofthewater/fuel mixtureinanenvironmentally acceptablemanner.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Fuel prefilter with water separator — replacing the filter element

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Pull out heaterplug(9)

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4.

Unscrewfilterelement (2)

5. 6.

Unscrewseparator(3)fromfilterelement (2) Cleantheseparator(3)

W M

To install

7. 8.

9. 10. 11. 12. Danger!

13. 14.

05/03

H Disposeofthefilterelementinanenvironmentally acceptablemanner. Ifdamaged, replacetheseparator Ensurethatthesealingringgrooveisclean!

Moistenthenewsealingrings(4and8)withengineoil. Screwtheseparator(3)withnewsealingring(8)ontothefilterelement(2)and finger-tighten. Screwthefilterelement (2)withnewsealingring(4)ontofilterhead(1) and H Donotusetoolstotighten! finger-tighten. Closedrainvalve(10). Fill theprefilterwithamanual fuel feedpump(7). Closethebleedscrew(6). R isk of accident duetovehiclestartingoffw hileengineisrunning. R isk of Wearclosedandsnug-fittingworkclothes. injury duetocrushingorburn sifcomponentsaretouchedduringthestart-up Donottouchhotorrotatingparts. procedureorwhentheengineisrunning. Starttheengineandbleedthefuel system. H Letth eenginerunforabout 1 minute. Thefuel systemis bledautomatically. Checktheprefilterforleaktightness.

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Fuel prefilter with water separator — replacing the filter element

225

Series 900<>Replacing the fuel filter — air cleaner — coolant

07.05.2003

N07.57-0226-01

N07.57-0225-01

* 1. 2.

To remove

3. 4.

Removescrewcap(1)withfilterinsert(3)andunclipthefilterinsertbypressing attheside Pull thesludgecollector(5) bythestrapsoutoffilterbowl(5). @ T akecarenottoletanyofthecollectedsludgeintothe filterbowl. Donotemptythesludgecollectorintothefilterbowl! Donotinanycircumstanceswipethefilterbowl. Cleanthescrewcap(1) andsludgecollector(4)

V

5. 05/03

Openthecaponthefuel tank; allowpressuretoescape, orclosethefuel cock. Unscrewthefuel filterscrewcap(1) usingasocketwrenchbit(SW36)

Onlyremovescrewcap(1)withfilterinsert(3)afterthefuel hasrunoutofthefilterbowl H

Powersystems • Industrial Engines Maintenance and Repair Series 457, 500 and 900 Advanced Training Series 900<>Replacing the fuel filter — air cleaner — coolant

226

w M 6. 7. 8. 9.

To install

Replacethesealingring(2) Insertnewfilterelement (3)inscrewcap(1) Insertthesludgecollector(4)intofilterbowl(5) Screwonthescrewcap(1)withfilterelement (3), andtighten. R isk of accident duetovehiclestartingoffw hileengineisrunning. R isk of ^ Danger ! injury duetocrushingorburn sifcomponentsaretouchedduringthestart-up procedureorwhentheengineisrunning S tarttheengineandbleedthefuel system. 10. Checkthefilterforleaktightnesswiththeenginerunning

11.

H Lightlygreasethesealingring. @ Placeatthecorrectinstallationlocation! Nm Securethevehicletopreventitstartingoffautomatically. Wearclosedandsnug-fittingworkclothes. Donottouchhotorrotatingparts. H Lettheenginerunforabout 1 minute. Thefuel systemis bledautomatically. Engine 904.9, 906.9

Nm Fuel filter

Captofuel filterhousing

[Nm]

25

M aintaining the air cleaner

Removetheaircleanerandcheckfordirtanddamage. Cleantheinsideoftheaircleanerhousingifnecessary. Theaircleanercartridgemust notbecleanedwithcompressedaircleaningequipment. Air cleaner cartridges m ust be replaced every 3 years at least. Engine coolant The engine coolant m ust be changed every 3 years at least.

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» … Die Mitarbeiter werden zukunftig in die Rolle personlicher W issensm anager hineinw achsen m ussen, die aktiv die Verantwortung fur ihre Qualifizierung ubernehm en … « Jurgen E. Schrempp

» … Staff must in future assume the role o f personal knowledge managers, who actively take responsibility fo r their own qualification … « Jurgen E. Schrempp

The finest automotive learning

D a im le r C h r y s le r AG D a im le rC h ry sle r Q uality M an agem en t

G lo b a l T ra in in g H P C T301

Zertifiziert nach /certified according to:

D — 7 0 5 4 6 S tu ttg a r t

> ISO 9001 (Nr.: 70104 M 0 3 4 TMS) > V D A 6.2

T e le le fo n + 4 9 (0) 7 1 1 / 1 7 6 2 4 4 4 In tr a n e t: h ttp : / / in t r a — g t . d a im le r c h r y s le r . c o m

1511 1209 02

1st edition

04.03

236