D5D Service Manual 2013
D5D Service Manual 2013
D5D Service Manual 2013
Diesel engine
D5D
S/N
2013 year
INDEX
1. Park the machine safe in accordance with the machine handbook instructions.
Figure 1
5. Using a suitable and safe cleaning solvent clean the filters (or fit new filters), make sure residual oil has been fully
removed.
8. Fit the gauze filters. Apply a thread locking compound to screws B. Make sure that the tapped holes in the rocker
cover are clean and free from excessive oil. Torque tighten the screws B to 8-10 Nm (6-7 lbf ft).
2
Foreword
WARNING
This warning symbol means risk of fatalities or personal injury if the instructions are not followed.
Description, engine
Numbering of cylinders
Figure 1
NOTICE
The governor's settings may only be adjusted by trained personnel at a central overhaul workshop.
NOTE!
An incorrectly adjusted governor may cause the engine not to meat the applicable regulations for emissions and
performance.
Figure 2
Figure 1
5. Rem
move the cha
arge-air pipe
e, oil pressure
e pipe, and tthe oil return pipe.
Figure 2
1. Turboch harger
2. Charge air pipe
3. Oil presssure pipe
4. Oil return pipe
5. Attachin ng yoke
6. Remmove the turbocharger.
7. Insttall protectivve plugs on the turbo and
a connections in the engine blocck for the prressure and return
lubrrication oil pipes.
6
Figure 3
1. Protectiive plug
Figure 4
1. 888000
050
2. 998648
85
Figurre 5
1. Lifting slin
ng
2. Lifting eyye
2
Engine,, disman
ntling
Op nbr 210
0-077
Figure 1
2. Loo
osen the fuel hose from th he filter braccket.
Rem
move the fueel pump and the bracket.
osen the fuel hose from th
Loo he fuel channel in the engine block.
Rem
move the fueel filter with 9996671.
9
Figure 2
Figure 3
Coolant pu
ump, wheel loader version
Figure 4
Coolant pu
ump, excavaator version
6. Remmove the bre
eather pipe fo
or coolant an
nd the pipe to
o the boost pressure
p sen
nsor. Plug the
e holes.
Figure 5
7. Rem
move the eng
gine speed governor,
g com
mplete with cabling.
c
Figure 6
8. Rem
move the sen
nsors for the d the camshaft.
e flywheel and
9. Rem
move the ove
erflow valve.
9
Figure 7
10. Rem
move the oil filter and fue
el filter with 9999179.
9 osen the ele
Loo ectric connecction for the oil
o pressure sensor.
s
Rem
move the oil cooler housiing and its ga asket.
Figure 8
Figure 9
13. Rem
move the dellivery (pressu ure) lines, co
omplete with rubber sealss.
NOTE!
The
e delivery (prressure) lines
s may not be e reused. Cover the injec
ctor's and the
e injection pu
ump's openin
ngs.
10
Figure 10
14. If th
he engine is equipped
e witth glow plugs
s, remove the cables for these from the cable con
nsole.
15. Disc nection from the stop sole
connect the electric conn enoid. Remoove the stop ssolenoid.
NOTE!
Be careful so thhat the contro
ol rod is not damaged.
d
Forr engine with electronic governor, rem
move the plug
g.
Figure 11
16. Pus
sh the controol rod to the stop
s position (control rod's end in the block) and ssecure it with
h 9998682.
17. Rem
move the ele ectric cabling from the cyllinder block.
18. Rem
move the ho olders for th he injectors. Mark up anda remove the injectorss. Use 9996 6400 together with
999
98007 if an in
njector is stuc
ck in the cylinder head.
NOTE!
Mak
ke sure that the injector'ss copper was sher comes o out as well.
Figure 12
19. If th
he engine is equipped
e witth glow plugs
s, remove these with .
20. Marrk up the roccker arm bridges and remmove them toogether with the
t rocker arrms.
11
Figure 13
Figure 14
22. Loo
osen the boltts for the cy
ylinder head.. Connect lift
fting slings to eyes and liftt away the cylinder
o the lifting e c
hea
ad.
Weight cylinder head:appro ox. 80 kg (17
76 lbs)
Figure 15
Injection pumps
p
23. Thee injection pu
umps are sp pring-loaded. Turn the fly
ywheel until the
t injection pump's spriing for cylind
der 1 is
st loaded. Th
leas hen the injec e camshaft's basic circle.
ction pump sttands on the
12
Rem
move the injeection pump for cylinder 1.
Marrk up the pum
mp unit.
Rep
peat the proccedure for the other cylinders.
Figure 16
24. Rem
move the rolller tappets with
w 1166840
09 and mark them togethe
er with the sh
him and the injection pum
mp.
Figure 17
Figure 18
27. Rem
move the oil suction pipe
e.
Figure 19
13
Vibration damper
d / fro
ont cranksh haft seal
28. Remmove the bellt pulley and the vibration
n damper.
Figure 20
Figure 21
Flywheel
30. Remmove the covver plate on the flywheel housing's lo
ower edge.
31. Remmove the pla
astic plugs be
etween the bolts
b that lock
k the flywhee
el bolts. Rem
move the flyw
wheel. Use 99
998681
as counterhold.
c Weight flywheel: approx x. 50 kg (1000 lbs)
Figure 22
3. Lifting eyes
e M12
32. Rem
move the flyw
wheel housin
ng.
14
Figure 23
33. Rem
move 999868 81.
34. Rem
move the tim
ming gear cas
sing.
Figure 24
35. Tap
p out the cran
nkshaft sealss on the timin
ng gear casin
ng and in the g with the oil pump.
e front casing
Pistons annd connectiing rod
36. Marrk the connecting rods' ca
aps. Remove e the caps with
w bearing halves.
h Retaiin the bearing halves.
Figure 25
37. Rem
move the pisstons, comple
ete with conn
necting rod.
15
Figure 26
Crankshafft
38. Cra
ank the engin
ne so that the
e crankshaft ends up at tthe top. Chec
ck that the ca
amshaft's ge
ear and crank
kshaft's
gea
ar are marked d.
eck that the main bearing
39. Che g caps are marked.
m Remmove the atta aching bolts and remove the caps an nd main
bea
aring halves.
Figure 27
Figure 28
1. Thrust washers
w
41. Rem
move the cra
ankshaft. We
eight cranksh
haft: approx. 75 kg (165 lbs)
16
Figure 29
42. Rem
move all bea
aring shells and
a thrust washers
w at main bearing 2. Mark the washers if they are to be
b used
aga
ain.
Figure 30
1. Bearing
g shell
2. Thrust washers
w
Figure 31
44. Che
eck the crank
kshaft accord
ding to .
Camshaft
45. Remmove the transfer gear fo
or the govern
nor. (Does no
ot apply to en
ngines with electronic
e governor).
17
Figure 32
46. Rem
move the cam mshaft together with the camshaft geear.
NOTE!
Work carefully sso that the ca
amshaft bearings are nott damaged.
Figure 33
47. Rem
move 999868 82.
48. Rem
move the locck bolt for the
e control rod.. Remove the
e control rod.
Figure 34
PTO
49. Rem
move the oil pipe betwee
en the power take-off (PT
TO) and the cylinder
c blockk.
18
Figure 35
50. Rem
move the powwer take-off (PTO).
Cylinder liner
move the cylinder liners. Use 999372
51. Rem 22 together w 5, 9993714 and 9993717.
with 9998675
NOTE! Mark upp the cylinderr liners if they
y are to be re
eused.
Figure 36
1. 999372 22
2. 9993714
3. 999867 75
4. 9993717
52. Che
eck-measuree the cylinderr liners accorrding to
53. Che
eck the camsshaft and cammshaft bearings accordin
ng to . If nee
eded, change
e bearings.
19
Engine, as
ssemblin
ng
Op nbr
n 210-078
Figure 1
Cyliinder liner
2 Make su
2. ure that the ccylinder liner's installation
n position and
d sealing surrfaces are co ompletely cle
ean.
3. Lubricatee the cylindeer liner with oil
o within the area marked d "X" in the fiigure. Install new O-rings
s.
Figure 2
4
4. Install th
he cylinder lin
ner in the correct position
n in the engine block. Drrive it down as
a far as posssible. Comp
pare the
cylinder liners' height in relation to
t the engine e block, see .
NOTE!
Do not use
u sealing ccompound. The T cylinder liner shall be thoroughly cleaned.
c
20
Cam
mshaft
5. Install th
he valve tapp
pets.
Figure 3
Figure 4
Cran
nkshaft
7. Check th
hat the oil cchannels are not clogged d and that th
he nozzles are
a not dama aged. Installl the piston cooling
nozzles in the correc
ct position in the engine block.
b Press in the piston
n cooling nozzzles as far as
a possible.
Figure 5
8. Install th
he bearing sh
hells in the en
ngine block.
21
Figure 6
9. Mark the
e crankshaft at the gear (to
( facilitate installation).
Figure 7
Figure 8
11. Install th
he crankshafft. The mark
ks must be in
n line. Use a ruler to ch
heck that the
e marks are in line throu
ugh the
middle ofo the crankshaft and cam
mshaft.
22
Figure 9
Figure 10
1
Figure 11
1
14. Install th
he bearing sh
hells in the be
earing caps, lubricate the a make sure that it is clean.
em with oil, and c
15. Lubricate bearing caps with oil and install them according to
e the main b o marking.
NOTE!
The main bearing ca aps are numb bered 1-5. Be
earing cap 1 closest to thhe flywheel e
end.
NOTE!
Make su
ure that the th
hrust washerrs on the cap
p fit correctly against the washers in tthe block.
23
Figure 12
Figure 13
Figure 14
1
Con
ntrol rod
18. Install th
he control rod
d, complete with
w guide sle
eeve.
Figure 15
1
Figure 16
1
Figure 17
1
Figure 18
1
1. 9992000
2. 9996872
Fron
nt casing with
w oil pummp
2 Lightly oil
25. o the oil pum
mp's rotor.
26. he gasket on the oil pump
2 Install th p/casing with
h some greasse.
25
Figure 19
1
2 Install th
28. he oil pump/ccasing withou
ut tightening down the bo n the casing upward and place it in line with
olts. Position
the oil su
ump's sealing surface.
Figure 20
2
Figure 21
2
Figure 22
2
Figure 23
2
33. Use piston ring comp pressor 99988687 and pre ess in the pis
ston, complette with conne
ecting rod, in
n the engine block.
NOTE!
Be carefful. The oil scraper rings are brittle and can easily be damaged. The pisto on ring comp pressor mayy not be
opened after the pisston has bee en placed in the tool. The en the piston
n rings may be damaged d. Always pre
ess out
the pisto
on first before
e opening the
e tool.
NOTE!
The flyw
wheel symboll stamped in the piston to
op, and the g
guide pins on
n the connectting rod shall face the flyw
wheel.
Figure 24
2
1. 9998687
34. Lightly oil
o the cranks
shaft pin. Preess the connnecting rod against the crrankshaft pin
n. Install the connecting rod
r cap
(according to markin
ng). Tighteninng torque, se
ee .
NOTE!
The big--end bearing bolts shall be
b replaced after
a each removal.
27
Figure 25
2
35. Check th hat bearings and pistons move smoothly by rotating the engin ne's cranksha
aft.
Oil suction
s pip pe/oil sump
he oil suction pipe with a new gasket. Tightening ttorque, see .
36. Install th
Figure 26
2
Figure 27
2
Figure 28
2
39. Install th
he oil sump. Tightening
T to
orque, see .
Figure 29
2
Figure 30
3
Figure 31
3
Figure 32
3
Figure 33
3
3. 9998678
4. dial indicatorr
5. spacer wash hers
30
Figure 35
Figure 34
Measuriing points
4 Compare
49. e the highest noted value
e of the 8 me
easuring poin
nts with and
d determine ssuitable cylin
nder head ga
asket.
Figure 36
3
Figure 37
3
1. Guide sleeve
es
31
Figure 383
Tightening diagram m for cylindeer head
53. Install th
he push rods according to g made when dismantling
o the marking g.
Figure 39
3
1. Push rods
54. Install th
he rocker armm bridges according to marking made when dis
smantling, an
nd align them
m in line witth push
rods and d valves. Tightening torqu
ue, see
Figure 40
4
55. Adjust th
he valve clea
arance, see
56. Remove e 9998681 an nd install the cover in the
e hole on the flywheel houusing.
57. Set the control
c rod in osition (inner position) witth 9998684 Installation tool. Install a new O-ring. Install
n its stop po
the stop solenoid. Tig
ghtening torqque:
32
NOTE!
For engiine with electtronic govern
nor, install th
he plug with a new O-ring
g. Lightly oil in the O-ring..
Figure 41
4
Inlett pipe.
58. Install th
he inlet pipe with
w new gas
skets. Tighte
ening torque, see .
Figure 42
4
Exh
haust manifold
59. Install th e for coolant with a new gasket
he outlet pipe g eal. Tightening torque, se
and se ee
Figure 43
4
60. Install th
he exhaust m
manifold. Tigh
htening torquue, see .
Injectors/delive ery (pressu
ure) lines, in
nstalling
61. For engiines equippeed with glow plugs, installl them. Use tool
t .
Tightening torque: seee
62. Install a new copper gasket (1) over
o ctor (using a little high tem
the injec mperature pa
aste, 116103
35)
33
Figure 44
4
1. Copper gaskket
63. Install th
he injectors.
NOTE!
Install th
he injector with the markin
ng (punch mark) facing th
he valve spriings.
Figure 45
4
1. Marking
64. Install th
he nozzle hollders in corre
ect position and
a tighten th
he bolts lighttly.
Figure 46
4
1. Retainer
2. Bolt, Torx E1 10
he gasket for the valve co
65. Install th over.
66. Install neew delivery ((pressure) lin
ne and rubbeer seal. Tightten the nuts by
b hand.
NOTE!
Delivery (pressure) lines may no ot be reused.. When instaalling delivery
y lines, the sealing fittings must fit ex
xactly in
pump an nd injector.
The delivery (pressu
ure) lines are
e deformed when
w tighten
ning and all delivery (pre
essure) lines
s must be tig
ghtened
with the same torque
e.
Reuse of
o delivery (prressure) lines may resultt in the engin
ne not running at full power.
34
67. NOT
TICE
The pressure lines may not be
e bent.
Tighten the bolts for the nozzle holders.
h Tightening torque
e, see
68. Tighten the delivery (pressure) lin
ne nuts. Tigh
htening torqu
ue: see .
Figure 47
4
69. Install th
he overflow vvalve with new
w copper ga
askets. Tighte
ening torque, see .
Figure 48
4
Valv
ve cover
70. Install th
he valve cove er. Tightening
g torque, see
e .
NOTE!
Make su ure that all ru
ubber gasketss end up corrrectly in the valve cover's
s groove.
Lub
bricating oil cooler
71. Install a new gasket. Install the lu
ubrication oil cooler. Tigh
htening torque, see .
Figure 49
4
35
72. Install th
he connection
n to the fuel line in the cy
ylinder block's trailing edg
ge. Tightenin
ng torque, se
ee
Figure 50
5
Coo
olant pump
73. Install th
he O-rings on
n the interme
ediate pipe.
NOTE!
Apply so ome lubricant 1141699 on n the O-rings
s for easier in
nstallation.
Figure 51
5
Figure 52
5
Figure 53
5
76. Install th
he plug for th
he control rod
d. Apply seallant (1) and new
n O-rings (2) on the co
oolant housin
ng. (Only applies to
excavato or version).
Figure 54
5
1. Sealant
2. O-rings
77. Install th
he coolant pu
ump/thermos
stat housing and
a use a ne
ew gasket.
Figure 55
5
Fuel pump
79. Install th
he fuel pump.
Figure 56
5
Figure 57
5
Figure 585
Tightening diagram m for govern nor
86. Install th
he sensors fo
or the flywheeel and camshaft (only appplies to exca
avator versio
on).
87. Install th
he crankcasee ventilation. Tightening to
orque, see
Figure 59
5
88. Install th
he breather p
pipe for coola
ant and the pipe
p for the charge-air sen
nsor
Figure 60
6
89. Remove
e the engine ffrom the worrk stand acco
ording to .
39
E
Engine, mountin
ng resp.. removing from
m work stand
s
Op nbr 210-0
O 075
L
Lifting eyes M10
M and M12 2
L
Lifting sling
S
Socket Torx 12
1
S
Socket Torx 18
1
S
Socket Torx 20
2
1. Install the engine mounts. Tig ghtening torque, see
2. Conn nect lifting eyyes and sling.
Figurre 1
1. Lifting slin
ng
2. Lifting eyye
2
way the engine from the work stand. Weight engiine: approx. 455 kg (100
3. Lift aw 03 lbs)
4. Remo ove the braccket for the work
w stand.
Figurre 2
1 - 88
8800050
5. Install the starter motor, if thiss was not don
ne together with
w the timin
ng gear casin
ng. Tightenin
ng torque, se
ee .
40
Figurre 3
Figurre 4
1. Turbocha arger
2. Charge a
2 air pipe
3 Oil pressure pipe
3.
4 Oil return
4. n pipe
5 Attaching
5. g yoke
8. Install the alterna
ator.
Install the V-belt.
Adjusst the alternator's positio
on by pressiing it in the arrow's dire
ection until the correct te
ension is ob
btained.
Tighttening torquee, see .
NOTE E!
It sho
ould be possible to press down the beelts approx. 10
1 mm betwe een the belt pulleys.
41
Figurre 5
Figurre 6
42
Compression test
Op nbr 210-002
9998694 Adapter
9988539 Pressure gauge
9998007 Adapter
Injection valves are removed and valve clearance checked.
Remove injection valves, see Injectors all, testing and adjusting incl removing and fitting
1.
Figure 1
Insert adapter (9998694) in injection valve bore with new seal ring.
2.
Figure 2
3.
Figure 3
Figure 1
Cylinder head
The cylinder head gasket is a multi-layer gasket with 1, 2 or 3 identification holes to indicate the three different thicknesses.
The choice of gasket thickness is determined by the piston protrusion over the cylinder head sealing surface. If new pistons
or a new cylinder block are fitted, the gasket thickness must be evaluated and changed if necessary.
Figure 2
Cylinder head gasket, marking
45
C
Cylinder
r head, rrecondittioning
Op nbr
O
V
Valve spring compressor
T
Tool for valve
e grinding
D test indiccator with ma
Dial agnetic base
D test indiccator with ang
Dial gled base
D
Depth gauge
S
Slide caliperss
C
C-clamps
1. Place
e the cylinder head in a vice.
v
NOTEE!
Use backing
b on th
he vice's jaw
ws so that the
e cylinder hea
ad is not dam
maged.
Figurre 1
Figurre 2
Figurre 3
8. Chec
ck the valve sseat rings an s. Wear limit for valve seat width, see
nd wear limits e .
Figurre 4
Figurre 5
10. Meas
sure the leng
gth of the valv
ve spring, wiith unloaded spring. Use slide caliperrs. Length, se
ee .
Figurre 6
NOTEE!
Chec
ck-measure tthe valve's de
epth in the cylinder head after grindin
ng the valve seats.
12. Install the valve sstem seal.
Figurre 7
14. NO
OTICE
Grea
at spring forrce. Make su
ure that the lock plate's seat is not damaged.
Use a valve sprin
ng tool for valve spring, in
nstall the collets.
Valve seat, changing
V c
15. The valve
v seats sshall be channged when th he measurem ment betweeen valve plate and the cyylinder head's
s plane
exceeeds the valuee given in the ons or when satisfactory sealing is no
e specificatio ot obtained. See
S .
Figurre 8
16. Grind
d down two edges
e on the
e head of a discarded valv
ve.
Figurre 9
48
17. Weld
d the valve in the valve se
eat.
NOTEE!
Work o that the cylinder head is
k carefully so s not damage
ed.
Figurre 10
Figurre 11
Figure 12
F Figure 13
In
nlet valve Exhhaust valve
1. Valve ness of edge (A)
e disc, thickn 1. Valve's edge thickne ess (A)
2. Valvee's seat angle (B) 2. Valve's seat angle (B)
3. Valvee seat's angle (C) 3. Valve seeat's angle (C)
Figurre 14
50
Rock
ker arm brid
dge
31. Chec
ck wear. Rep
place in case of abnormal wear.
Figurre 15
1. Pivot pins s
2. Adjusting
2 g screw
3 Rocker arm's contactt surface
3.
4 Diameterr
4.
ck that the oil ducts are open.
32. Chec
33. Assemble rocker arm and roc cker arm brid
dge. Install th
he lock rings.
51
Depth gauge
Slide calipers
Figure 1
3. Measure the cylinder liner collar at several places with a micrometer. Sealing surface for liner height, see
Cylinder block, specifications
Figure 2
4. Check the cylinder liner seat's depth at several places with a micrometer, see Cylinder block, specifications
Figure 3
1. Depth gauge
52
1. Remove the lock ring. Press out the piston pin. Remove the connecting rod.
Figure 1
Figure 2
1. Feeler gauge
5. Install the oil scraper ring (3).
Install the tapered compression ring (2) with the text "top" facing the combustion chamber.
Install the tapered compression ring (1) with the text "top" facing up.
Displace the piston rings' gap 120° in relation to each other.
NOTE!
The gap of oil scraper ring's inside spring shall be displaced 180° in relation to the ring gap.
53
Figure 3
1. Compression ring
2. Compression ring
3. Oil scraper ring
Figure 4
7. Check if the piston pin is worn. Piston pin diameter, see Crankshaft, specifications.
Figure 5
8. NOTE!
The ring gaps for the circlips must face the piston crown.
Figure 6
9. Install the piston together with the connecting rod. The flywheel symbol on the piston and the guide pins on the
connecting rod must be located on the same side.
Figure 7
1. Guide pin
Valves, description
The engines are equipped with one inlet and one exhaust valve per cylinder.
The upper area of the valve guide (on the valve stem) houses an O-ring (A). This O-ring seal should prevent a large level of
oil consumption and reduce the amount of hydrocarbons in the exhaust.
Valve rotation is achieved through the eccentric position of the rocker arm.
The valve springs have a prescribed direction of installation. The closely wound end of the valve spring must point toward
the cylinder head.
Rocker arm lubrication is a component of the centralized lubricating system. The oil is supplied via the tappets and push
rods.
Figure 1
Due to a new valve spring guide design, it is no longer possible to use a feeler gauge to adjust the valves of L40B machines
from SN 1913001 / 1923001 and L45B machines from SN 1943001 / 1953001 . For this reason, valve clearance
must be adjusted using the rotation angle disc.
Figure 2
Valve system
1. Jam nut
2. Adjustment screw
3. Rocker arm
4. Washer
5. Snap ring
6. Spring disc
7. Valve
8. Push rod
56
Valves, adjusting
Op nbr 214-012
NOTE!
Only adjust the valve clearance with cold engine.
Figure 1
Valve cover with pressure control valve
NOTICE
Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing
severe damage.
Figure 2
1. Exhaust valves: 1, 3, 5, 7
2. Inlet valves: 2, 4, 6, 8
4. Rotate the engine until the valves on cylinder no. 1 stand at "valve overlap".
NOTE!
Valve overlap means: exhaust valve not yet closed, inlet valve begins to open.
Figure 3
57
Figure 4
6. Tighten the lock nut to 20 ±2Nm (15 ±1.5 lbf ft). Check the valve clearance again with the feeler gauge.
Figure 5
7. Rotate the engine again, one full turn until the valves on cylinder 4 are at "valve overlap". Adjust the valve clearance
on valves marked black in the illustration.
Figure 6
9. Attach the valve cover and retainer plate. Tightening torque 11 Nm (8.1 lb ft)
NOTE!
Ensure that the rubber seals for the fuel lines are fitted in the correct position during assembly.
58
Figure 7
10. Attach pressure control valve to valve cover. Tightening torque 8.5Nm (6.3 lb ft)
Figure 8
Valve cover with pressure control valve
59
Valves, adjusting
Op nbr 214-012
NOTE!
Only adjust the valve clearance with cold engine.
Figure 1
Crankcase ventilation channel
Figure 2
4. Unscrew the cylinder head cover bolts and remove with gasket.
ÒÑÌ×ÝÛ
Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing
severe damage.
Figure 3
1. Exhaust valves: (EX) 1, 3, 5, 7
2. Inlet valves: (IN) 2, 4, 6, 8
60
5. Rotate the engine until the valves on cylinder no. 1 stand at "valve overlap".
NOTE!
Valve overlap means: exhaust valve not yet closed, inlet valve begins to open.
Figure 4
IN = inlet vavle
EX = outlet valve
Adjust valve clearance in accordance with the black mark on the adjustment chart for each cylinder.
Inlet valve: (IN) 90°
Figure 5
6. Undo the lock nut (1) and screw in the adjustment screw (2) until it makes contact.
Figure 6
NOTE!
The rocker arm must make contact (no gap) with the thrust washer (arrow) of the spring disc.
61
7. Position the rotation angle disc on the adjuster screw. Secure the magnet of the rotation angle disc to the cylinder
head. Set the rotation angle disc to "Null" in the direction of the arrow.
Figure 7
NOTE!
Take care not to turn the adjustment screw.
Figure 8
9. Counterhold the adjustment screw and tighten the lock nut to 20 ± 2 Nm (14.8 ± 1.5 lbf ft). Remove the rotation
angle disc.
Figure 9
62
10. Rotate the engine one revolution again until the valves of cylinder no. 4 are at "valve overlap". Adjust valve
clearance in accordance with the black mark on the adjustment chart for each cylinder.
Exhaust valve: (EX)150°
NOTE!
Follow steps 6 to 9 for adjusting exhaust valve clearance.
Figure 10
13. Fit the cylinder head cover and tighten the bolts alternately to 13 Nm (9.6 lbf ft).
15. Fit the crankcase ventilation. Tighten the bolts to 20 ± 2 Nm (14.8 ± 1.5 lbf ft.
16. Start the engine and check for leaks and proper operation.
63
Valves, adjusting
Op nbr 214-012
Feeler gauge
1. Rotate the engine's crankshaft until the valves overlap on cylinder no. 1. Overlapping of the vales means that the
exhaust valve is about to close. The inlet valve is about to open. No push rods can be rotated in this position.
(Cylinder 1 is located closest to the flywheel)
Figure 1
2. Adjust the valve clearance for each cylinder with feeler gauge according to the black markings in the figure. Valve
clearance, see Valve system, specification.
Figure 2
3. Tighten the lock nut. Tightening torque: Cylinder head, tightening torques.
Check the adjustment again with feeler gauge.
Figure 3
4. Rotate the crankshaft another revolution until the valves for cylinder 4 overlap. Adjust the valve clearance for each
cylinder with feeler gauge according to theblack markings in the figure. Mark the rocker arms of each adjusted
valve with chalk.
Figure 4
5. Tighten the lock nut according to Cylinder head, tightening torques.
6. Install a new valve cover gasket.
64
Figure 1
65
Camshaft, description
The camshaft is supported by 5 bearings. The sliding surfaces of the bearings and cams are inductively hardened.
Each bearing runs in a bearing bush that is pressed into the crankcase. There is one inlet, exhaust and injection pump cam
per cylinder. The axial stop for the camshaft is located in the timing case cover.
L40B machines from SN 1913001- / 1923001- and L45B machines from SN 1943001- / 1953001- are equipped with
unregulated internal exhaust gas recirculation (IEGR).
The camshaft has an addition cam - the caster cam. This ensures that the inlet valve briefly opens during the exhaust stroke
so that the exhaust also works in the engine intake system.
66
Figure 1
Steel ruler
Check with a steel ruler that the valve tappets' contact face against the camshaft is convex or plane. If the contact face is
concave, change valve tappets.
If the valve tappet is worn across the lifting surface, the tappet shall be scrapped, the "ditch" shows that the tappet has not
rotated.
A dark stripe on the outer edge of the lifting surface does not indicate that the surface is worn. It is the valve tappets'
condition that determines if a check of camshaft wear is necessary.
Check that the contact surfaces on the camshaft and the valve tappets do not have severe pitting damage. Pitting damage
may arise for varying reasons. The damage is caused by small bits of metal loosening from the hardened surface. Tappets
and camshaft with minor pitting damage may be used. Damage such as pitting usually does not get any worse.
Check that the camshaft bearing races and cam profiles are not abnormally worn. The cams may, for example, be worn
obliquely in an axial direction. This can, if the damage is light, be adjusted by honing.
Replace the camshaft if there is major damage and wear.
NOTE!
All valve tappets should also be replaced when replacing the camshaft.
Figure 2 Figure 4
67
Figure 3 Figure 5
Figure 6
Measuring points camshaft bearings
Op nbr
Figure 7
1. 9998695
Crankshaft, description
The forged crankshaft is provided with integrated balancing weights. The gear that drives the engine's timing gear and the
flange for the flywheel are shrink-mounted on the crankshaft.
Figure 1
69
Figure 1
70
Crankshaft, checking
Op nbr
Slide calipers
Screw micrometer
Main bearings
Figure 1
2. Diagram for measuring main bearing pins at points 1 and 2 in the planes a and b.
Bearing pin diameter, undersizes and wear limit, see Crankshaft, specifications.
Figure 2
3. Install the bearing shells in the main bearing caps, and install the main bearing caps in the engine block.
4. Measure the main bearing diameter at points 1 and 2 in the planes a and b.
Inside diameter and oversizes, see Crankshaft, specifications.
Figure 3
71
Thrust bearing
6. NOTE!
Before reworking the crankshaft, measure the width of the new thrust bearings. Measure the thrust bearing pin's
width. Use dial indicator for inside measurement. Measure the width of the crankshaft's thrust bearing pins.
Figure 4
7. Wipe clean the bearing cap, the thrust bearing and thrust washers. Install the thrust washers and measure the width
of the cap.
Figure 5
8. Determine the axial clearance. The big-end bearing pin's width, minus the measured width of the bearing cap and
thrust washers gives the current clearance. Permitted axial clearance, see Crankshaft, specifications.
Big-end bearing
9. Measure the big-end bearing pins. Big-end bearing diameter, undersize and wear limit, see
Crankshaft, specifications.
Figure 6 Figure 7
10. Check straightness of the crankshaft. Use dial indicator. Max. out-of-round on the middle bearing, see
Crankshaft, specifications.
72
1. Heat the new starter ring gear to +210 °C (+410 °F). If an oven is to be used, begin the work by heating the ring
gear. If a welding torch is to be used, heat the ring gear just before it is to be installed.
2. Drill a 10 mm (0.39 in) hole between two gear teeth on the old ring gear. Drill down 9 mm (0.35 in).
ÒÑÌ×ÝÛ
Do not drill in the flywheel. Risk of imbalance.
Figure 1
3. Secure the flywheel in a vice with soft jaws. Crack the starter ring gear by the drilled hole using a cold chisel.
Figure 2
4. Install the starter ring gear. Make sure that it bottoms against the flywheel flange. If necessary use a drift.
Figure 3
Figure 1
Thread tap M8
Brass drift 20 mm
Lock fluid
1. Drill a 6.7 mm hole in the system pressure valve. Thread the hole with an M8 thread tap or bolt.
Figure 1
2. Pull loose the system pressure valve with 9996400 together with 9998674 and remove it.
Figure 2
Figure 3
75
4. Drive in the system pressure valve, use brass drift 20 mm (0.787 in).
Figure 4
76
Figure 1
1. Rotor
2. Pressure chamber
3. Suction chamber
4. Crankshaft
77
Figure 1
3. Press down the compression spring and remove the stop washer. Remove the spring and valve peg for checking.
Also check the valve seat in the cover.
NOTE!
Be careful, use protective glasses. The valve's spring force is powerful. A high-quality spring compressor is required.
Figure 2
4. Remove the gear set and check that there is no abnormal wear. Replace the oil pump if needed.
Figure 3
5. Install the gear set.
NOTE!
The outer gear ring shall be turned with the beveled edge facing down.
78
6. Install the cover for the gear set. Tightening torque, see Lubrication and oil system, tightening torques.
Press down the compression spring and install the spring's stop washer.
NOTE!
Make sure that the spring's stop washer is adequately secured. Apply a thin layer of oil before installing.
Wait with installation of the crankshaft seal until the cover is located on the cylinder block.
79
Figure 1
2. Remove the two hollow flange bolts (17 mm) that hold the oil cooler.
Figure 2
Figure 3
5. Install a new aluminum washer on the hollow flange bolts. Use thread locking compound on the threads.
80
Figure 4
Figure 5
1. Plug
2. 9996685
3. Spacer
Figure 6
V1038431
1. 9996685
Figure 1
ÒÑÌ×ÝÛ
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
4. Remove the cable tie and unscrew the cab heat feed pipe (1) from the oil cooler housing.
5. Unplug the electric pin plug connections (2) and connectors (3) from the oil pressure switch.
7. Loosen and unscrew engine oil filter (6) and fuel filter (7).
8. Unscrew the bolts (1) and remove the fastening clamps. Unscrew the remaining bolts and remove the oil cooler
housing (2) with gasket.
Figure 2
82
9. Remove the oil cooler from its housing. Unscrew the plug (1).
Figure 3
10. Unscrew the collar bolts (oil cooler attachment) and remove the oil cooler.
Figure 4
11. Clean the oil cooler housing and all sealing surfaces.
12. Fit a new oil cooler in the oil cooler housing.
Figure 5
13. Put a new gasket (1) on the collar bolt and coat with assembly paste. Insert a new seal ring (2) in the groove and
apply a thin coating of oil.
Figure 6
83
14. Screw on and tighten the flange nuts. Tightening torque: pretension 80 Nm (59 lbf ft), re-tension 160 Nm (118
lbf ft).
15. Screw in the plug (1) and tighten to 80 Nm (59 lbf ft).
NOTE!
Coat new seal rings with assembly paste.
Figure 7
16. Fit the oil cooler housing with new gasket on the crankcase. Fit the retainer bolts and tighten alternately. Tightening
torque: pretension 3 Nm (2.2 lbf ft); re-tension 30 Nm (22 lbf ft).
17. Attach the cab heat feed pipe (1) to the oil cooler housing.
Figure 8
18. Plug in the electric pin plug connections (2) and connectors (3) to the oil pressure switch. Fit cable tie.
20. Screw on the engine oil filter (6) and fuel filter (7).
22. Start the engine and allow it to warm up so that the cooling system is completely filled and bled. Check for leaks.
Allow the engine to cool and then check level. Top up as necessary.
84
Figure 1
Fuel system diagram
1. Fuel tank
2. Primary filter (fuel pre-filter/water separator)
3. Fuel pump
4. Secondary filter (fuel filter)
5. Fuel line from secondary filter to the injection pump.
6. Injection pump
7. Line to injector
8. Injector
9. Pressure retention valve
10. Fuel return pipe
85
86
Figure 1
Fuel pump
Figure 1
1. Fuel filte er
2. Clean the sealin ng surface off filter holderr.
3. Lighhtly oil the ru
ubber seal off the new filte
er, or moisten
n with diesel.
4. Scrrew on the filtter by hand until
u the seall makes conttact, then tigh
hten anotherr half turn.
Figure 2
Fueel pre-filter
A. Filter element
B. Sight gllass
6. Clean the sealin ng surface off filter holderr.
7. Unsscrew sight glass
g from the filter insertt and clean.
8. Che eck seals forr damage and d replace if necessary.
n
9. Scrrew sight glasss on the new filter insertt.
10. Scrrew on the filtter by hand until
u the seall makes conttact, then tigh
hten anotherr half turn.
NOTE!
Air bleeding of tthe fuel systeem is not neccessary.
88
Figure 1
4. Detach fuel lines (1) and (2) from the fuel feed pump.
ÒÑÌ×ÝÛ
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
Figure 2
89
5. Slacken the bolts (1), move the fuel feed pump in the direction of the arrow and remove the V-belt (2).
Figure 3
6. Unscrew the bolts (1) and remove the fuel feed pump.
Figure 4
7. Unscrew the bolts (1), remove the fuel feed pump (2) and fasten the clamping strap (3) to the new fuel feed pump.
Tightening torque 20 ± 2 Nm (15 ± 1.5 lbf ft).
NOTE!
Note the installation position of the clamping strap.
Figure 5
90
8. Fit the clamping strap with fuel feed pump. Screw on the bolts (1) and position the V-belt (2).
Figure 6
9. Use a suitable tool to press the clamping strap in the direction of the arrow and tighten the bolts (1) to 30 Nm (22
lbf ft).
10. Check V-belt tension with the V-belt tension gauge. Press the button (1) against the V-belt until there is an audible
click. Read the measurement value at the intersection of the indicator arm and the scale (arrow).
Figure 7
NOTE!
Note the different units on the scale.
V-belt tension
Pretension after first installation 650 N
Run for 15 minutes under load and re-tension. 400 ± 50 N
NOTE!
If the set value is not achieved, the tensioning procedure must be repeated.
91
Figure 1
1. Shim
2. Hydraulic roller tappet for reduction of white smoke
Op nbr
Indicator
Magnetic base
NOTE!
9998685 Setting tool is used for engines with conventional roller tappets. 11668408 Setting tool is used for engines
with hydraulic roller tappets to reduce white smoke
The following methods only need to be performed after replacing engine block, camshaft or a roller tappet.
When only replacing a unit pump, see the section "Replacing unit pump".
Determining top dead centre
1. Install timing tool (protractor) 9998679 on tthe flywheel flange on the crank shaft.
NOTE!
Tighten the bolts thoroughly so that there is no clearance.
Figure 2
9998679
92
Figure 3
3. Position measuring rod 9998678 together with spacer washers above the piston relevant to the unit injector
for which the injection angle is to be determined.
Turn the crankshaft in the direction of rotation of the engine until the pointer has reached its turning point.
Set the graduated ring on the dial test indicator to zero.
Figure 4
9998678
To reduce the risk of obtaining
g the wrong measurement when determining top dead centre, the
following method must be performed:
4. Turn the crankshaft in the direction of rotation of the engine approx. 350° until there is 8 mm (0.315 in) left
to the top dead centre (the turning point of the test dial indicator).
Set the timing tool (protractor) 9998679 to zero.
Figure 5
5. Turn the crankshaft in the opposite direction until there is 8 mm (0.315 in) left to the top dead centre (the
turning point of the test dial indicator).
Read off the timing tool (protractor) .
93
Example: 50°.
Figure 6
Example: (0º + 50º) / 2 = 25º = Actual value. This corresponds to the top dead centre and should agree with
the turning point on the dial indicator.
Figure 7
NOTE!
Leave the timing tool (protractor) in position in preparation for the next stage in determining the injection
angle.
Figure 8
Measuring tolerance deviation, engine block (engine without hydraulic roller tappets for reduction
of white smoke)
We suggest copying the Value tables 1, 2 and 3
3.
8. Install the dial indicator on measuring tool 9998685, with a preload of 5 mm (0.20 in) o
on the millimetre
scale.
The hollow cylinder's measurement, Le, is calibrated to 150 mm (5.905 in).. Reset the scale ring to zero
against the gauge pointer.
94
Figure 9
1. 9998685
2. Dial test indicator
3. Pointer
4. Millimetre graduation
5. Graduated ring
9. Place the roller tappet without shim for the unit pump for which the timing is to be adjusted, on the base
circle of the camshaft.
Carefully insert 9998685 in the unit pump's hole.
Figure 10
NOTE!
Make sure that the guide on the roller tappet engages the groove in the location.
10. Turn the crankshaft until it is certain that the roller tappet is on the camshaft's base circle.
Figure 11
11. Measure "L" (Le - dial indicator X mm) and enter this in ""Calculation table 2.2".
Example:
Measuring tool: Le = 150 mm (5.905 in)
Dial indicator (X mm) = 2.18 mm (0.086 in)
95
The dial indicator shows 7.18 mm (0.283 in) when it is placed in the unit pump's hole.
The preload was 5 mm.
7.18 mm (0.283 in) - 5 mm (0.197 in) = 2.18 mm (0.086 in)
Figure 12
Measuring tolerance deviation, roller tappets and camshaft (engine without hydraulic roller tappets
for reduction of white smoke)
12. Read off the injection angle, Fbnom on the engine type plate.
Read off the lift of the camshaft,, Vhnom i Value table 1.
Enter both values in "Calculation
Calculation table 2.1
2.1".
Example:
Fbnom = injection angle = 6.0
Camshaft type = A
Vhnom = The value obtained on the timing tool (protractor) when the crankshaft has been turned so far that
the camshaft has affected the tappet 6.11 mm (0.241 in).
Turn the crankshaft in the engine's rotational direction until the dial indicator shows - (minus) Vhnom's value
of 6.11 mm (0.241 in), which is the camshaft lift.
Example:
7 mm (0.2756 in) - 6.11 mm (0.241 in) = 0.89 mm (0.035 in).
The dial indicator was reset to 5 mm (0.1968 in) preload on the gauge, and when it shows 0.89 mm (0.035
in), then Vhnom has been obtained.
96
Figure 13
13. The value shown on the timing tool (protractor) is the number of degrees at which the injection begins (e.g.
354.4°).
Figure 14
14. Read off the measurement "A" on the unit pump and enter this in the table Calculation table2.1.
Figure 15
15. Remove the measuring tool and the dial indicator. Conclude the calculations to determine the shim
thickness in Calculation table 2.2
97
NOTE!
Do not forget to change the EP-code
code on the engine's ID
ID-plate.
Figure 16
16. Allow the shim to slide into position along, for example, a screwdriver and down into the roller tappet.
Figure 17
Measuring tolerance deviation, engine block (engine with hydraulic tappets for reduction of white
smoke)
We suggest copying the Value tables 1, 2 and 3
3.
17. Install the dial indicator on 11668408, with a prel
preload
oad of 5 mm (0.20 in) on the millimetre scale.
The hollow cylinder's measurement, Le, is calibrated to 149.25 mm (5.876 in).. Reset the scale ring to zero
against the gauge pointer.
Figure 18
1. 11668408
2. Dial test indicator
3. Pointer
4. Millimetre graduation
5. Graduated ring
98
18. Place the roller tappet without shim for the unit pump for which the timing is to be adjusted, on the base
circle of the camshaft.
Carefully insert 11668408 in the unit pump's hole.
Figure 19
NOTE!
Make sure that the guide on the roller tappet engages the groove in the location.
19. Turn the crankshaft until it is certain that the roller tappet is on the camshaft's base circle.
Figure 20
20. Measure "L" (Le + Roller tappet's piston lift 1 mm - dial indicator X mm) and enter it in "Calculation
" table
2.2".
Example:
Measuring tool: Le = 149.25 mm (5.876 in)
The dial indicator shows 5,94 mm when it is positioned in the unit pump's hole. The preload was 5 mm. 5.94
- 5 mm = 0.94 mm
L= 149.25 mm (5.876 in) + 1 mm (0.039 in) - (+0.94 mm) (0.037 in) = 149.31 mm (5.878 in)
99
Figure 21
21. Read off the measurement "A" on the unit pump and enter this in the table Calculation table2.1.
Figure 22
22. Remove the measuring tool and the dial indicator. Conclude the calculations to determine the shim
thickness in Calculation table 2.2
NOTE!
Do not forget to alter the EP code on the engine type plate.
Figure 23
23. Allow the shim to slide into position along, for example, a screwdriver and down into the roller tappet.
NOTE!
Repeat the measuring procedures
es described in points 17
17-25 for each unit injector.
100
Figure 24
NOTE!
The measured value must be stated for when running in a test bench after completed repairs, alte
alteration or
modification of the governor with regard to the operating speed.
Figure 25
NOTE!
This may be done if no other machining has been carried out.
Example: Change of unit pump for cylinder 3 on a D5D with hydraulic roller tappets
Op nbr
1. Read off the EP-code
code for cylinder 3 from the engine type plate in the column "EP", e.g. 751.
Order of readings in the "EP" column on the engine type plate: line 1 = cylinder No. 1, line 2 = cylinder No.
2 and so on.
Figure 26
Engine type plate
2. Using the EP-code,
code, read off the corrected installation measurem
measurement, Ekfor the unit pump from Value table
3.
Figure 27
Manufacturing tolerance
NOTE!
If the value is not legible, remove any dirt, but not by scraping.
4. Read off the standard measurement for the unit pump, L0, from Calculation table 1.
5. Determine the theoretical shim thickness, Ts, according to the formula: Ts = Ek-(L
(L0 + A / 100)(also see
example in table Calculation table 1
1)
Figure 28
1. Control arm
NOTE!
The control rod must be locked in stop position with tool 9998684.
3. Coat the O-rings
rings on the unit pump with oil. Carefully enter the unit pump into its location.
Figure 29
1. Control rod
2. Shims for pump element
3. Roller tappet for pump element
103
Check that the unit pump's link arm is in the control rod's groove before it is pressed down.
4. Position the flange with the chamfer directed toward the body of the unit pump.
Coat the bolts with oil and tighten them evenly.
Tightening torque, see step 1 and 2,
Figure 30
Figure 31
NOTE!
Check that the control rod moves easily after installing each unit pump
7. Repeat points 1-6
6 for the other cylinders.
NOTE!
Check that the control rod moves easily after installing each unit pump
9. Loosen the bolt on measuring tool 9998684 and turn it away from the control rod, and tighten the measuring
tool's bolt on the measuring position.
Figure 32
1. 9998684
9. Measure from the tool to the control rod stop position.
104
Figure 33
10. Measure from the measuring tool to the starting position for the control rod.
Example: 13.6 mm (0.535 in) The difference between the start and stop positions is the control rod stroke.
Control rod's smallest stroke =16. 8 mm (0.661 in).
Control rod's stroke: 30.5 - 13.6 = 16.9 mm (1.20 - 0.535 = 0.665 in).
Determining thickness of shim when injector is to open
NOTE!
Determining the thickness of shim shall be done when changing engine block, camshaft or roller tappet.
Use Calculation table 2.1 and Calculation table 2.2below for calculating the shim's thickness.
NOTE!
After the shim thickness has been determined, a new EP-code must alwaysbe retrieved from Value table 3 in
order to allow a correct, future replacement of the pump.
105
Value table 2, information about shim thicknesses (engines with hydraulic roller tappets for reduction of
white smoke), L0=136.8 mm
Value table 2, information about shim thicknesses
Theoretical thickness, Ts Shim thickness, Ss Theoretical thickness, Ts Shim thickness, Ss
4.625 - 4.6749 mm 4.65 mm 5.575 - 5.6249 mm 5.60 mm
(0.1831 - 0.18697 in) (0.1831 in) (0.2195 - 0.22145 in) (0.220 in)
4.675 - 4.7249 mm 4.70 mm 5.625 - 5.6749 mm 5.65 mm
(0.18406 - 0.18602 in) (0.1850 in) (0.2215 - 0.22342 in) (0.222 in)
4.725-4.7749 mm 4.75 mm 5.675 - 5.7249 mm 5.70 mm
(0.18602 - 0.18800 in) (0.1870 in) (0.22342 - 0.22539 in) (0.224 in)
4.775 - 4.8249 mm 4.80 mm 5.725 - 5.7749 mm 5.75 mm
(0.18800 - 0.19000 in) (0.1900 in) (0.2254 - 0.22736 in) (0.226 in)
4.825 - 4.8749 mm 4.85 mm 5.775 - 5.8249 mm 5.80 mm
(0.19000 - 0.19192 in) (0.1909 in) (0.2274 - 0.22933 in) (0.228 in)
4.875 - 4.9249 mm 4.90 mm 5.825 - 5.8749 mm 5.85 mm
(0.19192 - 0.19389 in) (0.1929 in) (0.2293 - 0.23129 in) (0.230 in)
4.925 - 4.9749 mm 4.95 mm 5.875 - 5.9249 mm 5.90 mm
(0.19192 - 0.19586 in) (0.1949 in) (0.2313 - 0.23326 in) (0.232 in)
4.975 - 5.0249mm 5.00 mm 5.925 - 5.9749 mm 5.95 mm
(0.19586 - 0.19783 in) (0.1968 in) (0.2333 - 0.23523 in) (0.234 in)
5.025 - 5.0749 mm 5.05 mm 5.975 - 6.0249 mm 6.00 mm
(0.19783 - 0.19980 in) (0.1988 in) (0.2352 - 0.23720 in) (0.236 in)
5.075 - 5.1249 mm 5.10 mm 6.025 - 6.0749 mm 6.05 mm
(0.19980 - 0.20177 in) (0.2008 in) (0.2372 - 0.23917 in) (0.238 in)
5.125 - 5.1749 mm 5.15 mm 6.075 - 6.1249 mm 6.10 mm
(0.20177 - 0.20374 in) (0.2027 in) (0.2392 - 0.24114 in) (0.240 in)
5.175 - 5.2249 mm 5.20 mm 6.125 - 6.1749 mm 6.15 mm
(0.20374 - 0.20570 in) (0.2047 in) (0.2411 - 0.24311 in) (0.242 in)
5.225 - 5.2749 mm 5.25 mm (0.207 in) 6.175 - 6.2249 mm 6.20 mm
(0.20570 - 0.20767 in) (0.2067 in) (0.2431 - 0.24507 in) (0.244 in)
5.275 - 5.3249 mm 5.30 mm 6.225 - 6.2749 mm 6.25 mm
(0.20768 - 0.20964 in) (0.2087 in) (0.2451 - 0.24704 in) (0.246 in)
5.325 - 5.3749 mm 5.35 mm 6.275 - 6.3249 mm 6.30 mm
(0.20965 - 0.21161 in) (0.2106 in) (0.2470 - 0.24901 in) (0.248 in)
5.375 - 5.4249 mm 5.40 mm 6.325 - 6.3749 mm 6.35 mm
(0.21161 - 0.21358 in) (0.2156 in) (0.2490 - 0.25098 in) (0.250 in)
5.425 - 5.4749 mm 5.45 mm 6.375 - 6.4249 mm 6.40 mm
(0.21161 - 0.21555 in) (0.2146 in) (0.2510 - 0.25295 in) (0.252 in)
5.475 - 5.5249 mm 5.50 mm
(0.21555 - 0.21752 in) (0.2165 in)
5.525 - 5.5749 mm 5.55 mm
(0.21752 - 0.21948 in) (0.2185 in)
109
Value table 3, information about EP-codes (engines with hydraulic roller tappets for reduction of white
smoke), L0= 136.8 mm
Value table 3, information about EP codes
Ek EP code Ek EP code Ek EP code Ek EP code
142.0 mm 700 142.7 mm 728 143.4 mm 756 144.1 mm 784
(5.5905 in) (5.6181 in) (5.6457 in) (5.6732 in)
142.025 mm 701 142.725 mm 729 143.425 mm 757 144.125 mm 785
(5.5915 in) (5.6191 in) (5.6466 in) (5.6742 in)
142.05 mm 702 142.75 mm 730 143.45 mm 758 144.15 mm 786
(5.5925 in) (5.6201 in) (5.6476 in) (5.6752 in)
142.075 mm 703 142.775 mm 731 143.475 mm 759 144.175 mm 787
(5.5935 in) (5.6210 in) (5.6486 in) (5.6762 in)
142.1 mm 704 142.8 mm 732 143.5 mm 760 144.2 mm 788
(5.5945 in) (5.6220 in) (5.6496 in) (5.6771 in)
142.125 mm 705 142.825 mm 733 143.525 mm 761 144.225 mm 789
(5.5955 in) (5.6230 in) (5.6506 in) (5.6781 in)
142.15 mm 706 142.85 mm 734 143.55 mm 762 144.25 mm 790
(5.5964 in) (5.6240 in) (5.6516 in) (5.6791 in)
142.175 mm 707 142.875 mm 735 143.575 mm 763 144.275 mm 791
(5.5974 in) (5.6250 in) (5.6525 in) (5.6801 in)
142.2 mm 708 142.9 mm 736 143.6 mm 764 144.3 mm 792
(5.5984 in) (5.6260 in) (5.6535 in) (5.6811 in)
142.225 mm 709 142.925 mm 737 143.625 mm 765 144.325 mm 793
(5.5994 in) (5.6270 in) (5.6545 in) (5.6821 in)
142.25 mm 710 142.95 mm 738 143.65 mm 766 144.35 mm 794
(5.6004 in) (5.6280 in) (5.6555 in) (5.6831 in)
142.275 mm 711 142.975 mm 739 143.675 mm 767 144.375 mm 795
(5.6014 in) (5.6289 in) (5.6565 in) (5.6840 in)
142.3 mm 712 143.0 mm 740 143.7 mm 768
(5.6023 in) (5.6299 in) (5.6575 in)
142.325 mm 713 143.025 mm 741 143.725 mm 769
(5.6033 in) (5.6309 in) (5.6584 in)
142.35 mm 714 143.05 mm 742 143.75 mm 770
(5.6043 in) (5.6319 in) (5.6594 in)
142.375 mm 715 143.075 mm 743 143.775 mm 771
(5.6053 in) (5.6329 in) (5.6604 in)
142.4 mm 716 143.1 mm 744 143.8 mm 772
(5.6063 in) (5.6338 in) (5.6614 in)
142.425 mm 717 143.125 mm 745 143.825 mm 773
(5.6073 in) (5.6348 in) (5.6624 in)
142.45 mm 718 143.15 mm 746 143.85 mm 774
(5.6083 in) (5.6358 in) (5.6634 in)
142.475 mm 719 143.175 mm 747 143.875 mm 775
(5.6092 in) (5.6368 in) (5.6644 in)
142.5 mm 720 143.2 mm 748 143.9 mm 776
(5.6102 in) (5.6378 in) (5.6653 in)
142.525 mm 721 143.225 mm 749 143.925 mm 777
(5.6112 in) (5.6388 in) (5.6663 in)
142.55 mm 722 143.25 mm 750 143.95 mm 778
(5.6122 in) (5.6397 in) (5.6673 in)
142.575 mm 723 143.275 mm 751 143.975 mm 779
(5.6132 in) (5.6407 in) (5.6683 in)
142.6 mm 724 143.3 mm 752 144,0 mm (5.67 in) 780
(5.6142 in) (5.6417 in) (5.669 in)
142.625 mm 725 143.325 mm 753 144.025 mm 781
(5.6151 in) (5.6427 in) (5.6703 in)
142.65 mm 726 143.35 mm 754 144.05 mm 782
(5.6161 in) (5.6437 in) (5.6712 in)
142.675 mm 727 143.375 mm 755 144.075 mm 783
(5.6171 in) (5.6447 in) (5.6722 in)
111
[ 1]The unit pump serial number may be used to make it easier to keep the parts together.
[ 2]The unit pump serial number may be used to make it easier to keep the parts together.
[ 3]The unit pump serial number may be used to make it easier to keep the parts together.
112
NOTE!
The injection pumps shall not be installed during this operation.
Figure 1
1. 9998684
2. Measure from the measuring tool to the control rod's stop position.
Figure 2
3. Measure from the measuring tool to the control rod's starting position. Use slide caliper.
The difference between the start and stop positions is the stroke of the control rod.
Example:
Stop position = 30.7 (1.209 in)
Starting position = 13.4 mm (0.528 in)
Control rod's stroke = 17.3 mm (0.681 in)
Stated measurement = 17.0 mm - 17.5 mm (0.669 - 0.689 in)
Figure 3
113
4. Turn the measuring tool according to fig. Press the control rod to the stop position by hand with the stop bolt.
NOTE!
The stop bolt should only be tightened by hand.
Figure 4
114
Control rod
Op nbr
9992000 Handle
9998696 Installation tool
NOTE!
With electronic governor, the new x-measurement must be added to the control unit.
Figure 1
2. Drill out the spring pin on the guide sleeve and remove it.
NOTE!
Always replace guide sleeve when dismantling the control rod.
3. Assembly order:
1. Control rod
2. Compression spring
3. Washer
4. Guide sleeve
5. Spring pin
4. Pay attention to in which direction the control rod is installed compared to the guide sleeve.
Figure 2
115
5. Install the spring pin according to the figure.
Figure 3
7. Remove the plug and then drive out the guide sleeve at the front end.
Figure 4
1. 9992000
8. Place the guide sleeve on the installation drifts with the bevel facing the crankcase.
Figure 5
1. 9998696
116
9. Place installation tool 11668404 together with installation drifts against the engine block and secure it with a bolt.
Figure 6
1. 9998696
10. Drive in the guide sleeve until the short installation drift 9998696 bottoms out against the holder.
Figure 7
1. 9998696
117
Injectors
s all, tes
sting and
d adjustting incl removing and ffitting
O nbr 237-0
Op 074
In
njection valve, removiing
1. Remo ove pressurre control valve
v and valve cover. Unplug cab
ble plug fro
om stop sollenoid, gove
ernor and
temperature senssor. Turn reta
aining plate to
t one side.
2. Remo ove injector lines.
Figurre 1
1. Injector lines
NOTEE!
Used
d delivery pip
pes must not be re-installed.
3. Remo
ove clamping
g claw.
Figurre 2
4. Remo
ove injection
n valves.
Figurre 3
1. 9996400
2. 9998007
2
118
NOTE E!
If seiz
zed, use puller 9996400 with adapterr 9998007.
Optimal cleanliiness must be observe ed when tessting injectoors. Only usse clean tessting oil ac
cc. to ISO
4113 or clean dieesel oil.
NOTE E!
The injection
i valv
ves are leak
k-proof. The incoming fue
el cannot flo
ow away and d collects ab
bove the neeedle in the
spring chamber o of the nozzle
e holder. The
en the hand lever of the
e nozzle teste
er can no lo
onger be actiivated. To
release the presssure in the spring chammber before each test, the
t clamping
g nut must beb released and then
retigh
htened as sp
pecified.
Check injec
C ction valve.
5. Loosen clamping nut approx. 180° and tig
ghten again. Tightening torque 30 +10 Nm (22 +7.4
+ lbf ft)
Figurre 4
Figurre 5
Adjust injec
A ction valve.
9. If the
e opening pre essure has to
t be correctted: remove injection vallve from nozzzle tester. Unscrew
U clam
mping nut,
remoove all parts.
Figurre 6
Figurre 7
Components, injjection valv ve
1. Clamping g nut
2 Nozzle
2.
3 Spacer
3.
4 Thrust pin
4. n
5 Thrust sp
5. pring
6 Adjusting
6. g washers
11. Retes
st injection vvalve on nozz
zle tester.
Check injec
C ction valve ffor leaks
12. Dry nozzle
n and noozzle holder, blow dry wiith compress sed air.
13. Slowly press the tester lever down
d until appprox. 2 MPaa (20 bar) (29
90 psi) below
w the previou
us opening pressure.
p
14. The nozzle
n seals tight if no drrops fall withiin 10 second
ds.
Figurre 8
120
Dropp test
15. If a drop falls, the
t injection valve mustt be disman
ntled and the leak elimiinated by clleaning. If th
his is not
succeessful, the noozzle must be
b replaced.
Figurre 9
Dropp falls
V
Vibration annd jet test
16. Disco onnect testerr pressure ga auge
The vibration
v tesst allows an audible test of ease of movement of o the nozzle e needle in the
t nozzle body.
b New
injecttion valves have differentt vibration beehaviour fromm used ones.
Wearr in the need dle area caus
ses deteriora ation. If a noz
zzle does no ot vibrate desspite cleaning, it must be
e replaced
with a new one.
A useed injection valve
v must rattle
r audiblyy at fast leverr action so itt injects with good atomis
sation. The jet
j pattern
may differ considerably from thatt of a neww injection va
alve.
In
nstall injecttion valve
17. Using g a little greaase, push a new
n seal ring
g on the injecction nozzle.
Figurre 10
1. Sealing ring
18. Inserrt the injection valves with
h the recess against the valve
v spring..
Figurre 11
1. Recess
19. Fit cla
amping claw
w and looselyy install screw
w.
20. Attacch new injection pipes witth rubber sea
als. Tighten lock
l nuts fing
ger-tight.
121
NOTE E!
When n fitting injec
ction pipes, th
he seals must be precise
ely positioned to each other. Bending
g the injectio
on pipes is
not permitted.
Used
d delivery pip
pes must not be re-installed.
21. Tightten screws on clamping claw.
c Tighten
ning torque: 16 +5 Nm (11.8 +3.7 lb
bf ft)
Figurre 12
Figurre 13
23. Attac
ch valve cove
er.
122
Turbocharger, description
The turbocharger is driven by the exhaust gasses as they pass through the turbine housing.
The exhaust gas flow causes the turbine rotor in the turbine housing to rotate. The compressor rotor is positioned on the
same shaft as the turbine rotor. The compressor rotor is positioned in a housing which is connected between the air cleaner
and the engine induction manifold.
When the compressor rotor rotates, air is drawn from the air cleaner. The air is compressed and forced into the engine
cylinders, after it first has been cooled down while passing through the intercooler.
Figure 1
Turbocharger, principle diagram
1. Ejector - pre-cleaner
2. Main filter with control light in instrument panel
3. Secondary filter
Figure 1
Cooling system
125
Figure 1
7. Remove the insert from the coolant pump. Fit new seal rings (arrows) and coat with assembly paste.
Figure 2
Insert, coolant pump and thermostat housing
9. Fit the coolant pump with new gasket (1) to the crankcase. Apply sealant to the retainer bolts and tighten.
Figure 3
126
Figure 4
11. Remove the fuel feed pump and tension the V-belt; see Feed pump, replacing
13. Start the engine and allow it to warm up so that the cooling system is completely filled and bled. Check for leaks.
Allow the engine to cool and then check level. Top up as necessary.
127
Thermostat, replacing
Op nbr 262-098
ÒÑÌ×ÝÛ
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
4. Unscrew the retainer bolts (1) from the thermostat housing hose studs (2).
Figure 1
Figure 2
7. Coat the seal ring of the new thermostat with assembly paste.
9. Fasten the hose studs to the thermostat housing. Tightening torque 30 Nm (22 lbf ft).
11. Start the engine and allow it to warm up so that the cooling system is completely filled and bled. Check for leaks.
Allow the engine to cool and then check level. Top up as necessary.
128
Информация об обслуживании
Figure 1
NOTE!
If the fan speed in the tropics version is more than 3000 ±50 rpm (50 ±0.83 rps), the relief valve on the fan motor
must be set to max. 17 MPa (170 bar) (2466 psi).
5.
Figure 2
Checking point
1. Hose
2. L-connector
3. Measurement connection
Unscrew the hose from fan motor and install checking point.
6. Fasten hose to L-connector and connect pressure gauge (bis max. 250 bar, 3626 psi).
8. Read display on pressure gauge, max. 10.7 MPa (107 bar) (1552 psi)for standard or max. 17 MPa (170 bar)
(2466 psi) in tropics version.
Figure 3
10. Turn adjustment screw on relief valve clockwise "Pressure rise" or counter-clockwise "Pressure drop" until the
pressure gauge shows a pressure of max. 10.7 MPa (107 bar) (1552 psi) as standard or max. 17 MPa (170 bar)
(2466 psi) in tropics version.
Metric coarse and fine threads tensile strength 8.8 Nm kgf m lbf ft
M6 10 ±2 1.0 ±0.2 7.4 ±1.5
M8 24 ±5 2.4 ±0.5 18 ±3.5
M10 48 ±10 4.8 ±1.0 35 ±7.4
M12 85 ±18 8.5 ±1.8 63 ±13.0
M14 140 ±25 14.0 ±2.5 103 ±18.0
M16 220 ±45 22.0 ±4.5 160 ±33.0
M20 430 ±85 43.0 ±8.5 320 ±63.0
M24 740 ±150 74.0 ±15.0 550 ±110.0
Metric coarse and fine threads, tensile strength 10.9 Nm kgf m lbf ft
M6 12 ±2 1.2 ±0.2 9 ±1.5
M8 30 ±5 3.0 ±0.5 22 ±3.5
M10 60 ±10 6.0 ±1.0 44 ±7.5
M12 105 ±20 10.5 ±2.0 78 ±14.5
M14 175 ±30 17.5 ±3.0 130 ±22
M16 275 ±45 27.5 ±4.5 204 ±33
M20 540 ±90 54.0 ±9.0 400 ±66
M24 805 ±160 80.5 ±16.0 594 ±118
Engine, specification
General D5D
Engine, capacity
Engine
Engine oil, including filter 14 litres (3.6 US gal)
Cylinder liner
Type Wet, replaceable
Inside diameter 108 +0.02 mm (4.252 +0.001 in)
Liners' height in relation to cylinder block 0.03-0.08 mm (0.0012-0.0031 in)
Cylinder liner's sealing surface against cylinder block (liner 9.0 -0.02 mm (0.354 -0.001 in)
collar)
Distance liner collar's seat (Distance to block face)
8.935 ±0.015 mm (0.3518 ±0.0006 in)
Number of seal rings per cylinder liner
2
Max. permitted wear (wear limit) 108.1 mm (4.2559 in)
134
Camshaft
General
Drive Gear
Radial clearance 0.050–0.124 mm (0.0020–0.00490 in)
End float 0.1–0.5 mm (0.0040–0.020 in)
Bearing bushings
Quantity 7
Bearing bushings, inside diameter 65.0 +0.054 mm (2.559 +0.00213 in)
Wear limit 65.08 mm (2.562 in)
Thickness 1.988 +0.012 mm (0.0783 +0.00047 in)
Position of the bearing bushing 2 +0.2 mm (0.08 +0.008 in)
nearest to the flywheel from the engine block's outer edge
135
Crank mechanism
Crankshaft
Main bearings
Type Replaceable
Inside diameter 85.030–85.066 mm
(3.3476-3.3490 in)
Thickness, standard 2.727-2.735 mm (0.107362-0.107677 in)
Oversize 0.25 mm 2.852-2.860 mm (0.112283-0.112598 in)
(0.0098 in)
Pistons
Piston rings
Compression rings
Quantity 2
Piston ring clearance in grooves:
upper compression ring tapered
lower compression ring 0.17 mm (0.0067 in)
Piston ring gap:
upper compression ring 0.8 mm (0.032 in)
lower compression ring 2.5 mm (0.098 in)
Oil scraper ring
Quantity 1
Width, including spring 3 mm (0.118 in)
Piston ring clearance in grooves 0.10 mm (0.004 in)
Piston ring gap 1.15 mm (0.0453 in)
Connecting rods
Parallelism (twist)
Measurement "a" max. 0.05 mm (0.0020 in) over a distance of x = 100 mm (3.94 in)
Figure 1 Figure 2
Straightness
Permissible tolerance "A" to "B": 0.05 mm (0.0020 in) over a distance of x = 100 mm (3.94 in)
137
Flywheel
Feed pump excess pressure valve, opening pressure 600 ±50 kPa (6 ±0.5 bar) (87 ±7.3 psi)
Overflow valve, opening pressure 50 ±5 kPa (0.5 ±0.05 bar) (7.3 ±0.7 psi)
Fuel filter
Cooling system
Type Pressurised closed system
Pressure valve opens at 90 kPa (0.9 bar) (13 psi)
Coolant, volume approx. 6 litres (1.6 US gal)
Coolant pump
Valve mechanism
Valves
Valve head diameter: .
inlet 48.0 ±0.1 mm (1.8898 ±0.0039 in)
42.0 ±0.1 mm (1.6535 ±0.0039 in)
exhaust
Stem diameter: .
inlet 8.965–8.980 mm (0.3530-0.3535 in)
. 8.945–8.960 mm (0.3522-0.3528 in)
exhaust
Valve's seat angle: .
inlet 29.5°
exhaust 44.5°
Valve disc's edge (wear tolerance): .
inlet .
exhaust min. 2.1 mm (0.0827 in)
min. 1.8 mm (0.0709 in)
Seat's angle in cylinder head: .
inlet 30°
exhaust 45°
The valve seat shall be ground down until the distance from
the valve disc (new valve) to the cylinder head's face is:
inlet/exhaust
Figure 1
NOTE!
As spare parts the valve seats are pre-finished and shall not need any further grinding.
142
Valve guides
Inside diameter: .
inlet 9.025 +0.025 mm (0.3553 +0.00098 in)
exhaust
Clearance, valve stem - guide .
inlet 0.10 mm (0.0039 in)
exhaust 0.13 mm (0.0051 in)
Valve springs
64.70 ±1.3 mm (2.547 ±0.0512 in)
Length, unloaded
Diameter, 4.5 mm (0.177 in)
143
Make Schwitzer
Lubrication system Force-feed lubrication
Max. radial clearance, compressor side 0.88 mm (0.0350 in)
Max. end float 0.10 mm (0.0039 in)
Max. permissible back pressure in exhaust line 7.5 kPa (0.075 bar) (1.09 psi)
144
Crankshaft
NOTE!
The bolts may not be reused.
Figure 1
Applying sealant to timing gear casing
145
Vibration damper
Screw plugs
Figure 2
Attaching bolts .
Step 1 50 Nm (39 lbf ft)
Step 2 130 Nm (96 lbf ft)
Step 3: Angular tightening 90°
Figure 1
Tightening diagram, cylinder head
Valve mechanism
Valve cover
Crankcase ventilation
Step 1: 20–30 Nm
(14.75–22.13 lbf ft)
Step 2: 60°
Angular tightening
Step 3: 30°
Step 1: 20–30 Nm
(14.75–22.13 lbf ft)
Step 2: 60°
Angular tightening
Step 3: 60°
Step 1: 30–40 Nm
(14.75–22.13 lbf ft)
Step 2: 60°
Angular tightening
Step 3: 60°
Flywheel housing
Oil sump
Oil cooler
Oil trap
Oil pump/casing
Fuel lines
Injection pumps
Flange screws .
Step 1: Tightening 5 Nm (4 lbf ft)
Step 2: Loosen the bolts 60° (counter-clockwise)
Step 3: Turn the injection pump to stop +1 Nm (0.7 lbf ft)
Sep 4 counter-clockwise
Step 5 60°
Step 6 7 Nm (5.2 lbf ft)
Step 7 10 Nm (7.4 lbf ft)
30 Nm (22.1 lbf ft)
Control rod
Stop solenoid
NOTE!
For electronic governors, the x-measurement is introduced as a value in the control unit. An electronic governor is not
unique with a calibrated x-measurement.
Figure 1
150
Inlet pipe
Exhaust manifold