Service and Maintenance

6
6.1 Lubrication System
6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air System
6.5 Belt Drives
6.6 Adjustments
6.7 AccessoriesService and Maintenance

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 Service and Maintenance 6.1 Lubrication System

6.1.1 Oil Change Intervals

6 Installed engines
Lube oil intervals in OH
Naturally aspirated engines
Lube oil intervals in OH
Turbocharged engines
API classification CC 1) CD/CE 1) CD/CE/CF-4 —
● The oil change intervals are dependent on the Lube oil quality
CCMC classification D4 D5 2) (SHPD) 3) D4 D5 2) (SHPD) 3)
engine application and the quality of the lube
oil. Normal oil usage, e.g.:
250 500 250 500
● If the engine runs fewer hours during the year Road vehicles, cranes, construction machinery, ships,
than stated in the table, the oil should be changed electrical units, pumps, rail-run vehicles
at least once a year.
Heavy-duty oil usage, e.g.:
● The table refers to the following conditions: Combine harvesters, emergency pumps, underground 125 250 125 250
– For diesel fuel: sulfur content max. 0.5% by equipment, sweeping machines, winter operation
weight. equipment, emergency power generating units
– Continuous ambient temperatures down to
-10 °C (+14 °F). Lube oil intervals in km Lube oil intervals in km
Vehicle engines
Naturally aspirated engines Turbocharged engines
● If the sulfur content is > 0.5 to 1% or the
continuous ambient temperature below -10 °C API classification CC 1) CD/CE 1) CD/CE/CF-4 —
(+14 °F), the intervals between oil changes should Lube oil quality
CCMC classification D4 D5 2) (SHPD) 3) D4 D5 2) (SHPD) 3)
be halved.
Annual average
Service kilometrage speed approx.
group km km/h

I to 30 000 20 5 000 10 000 5 000 10 000

II more than 30 000 40 10 000 20 000 10 000 20 000

to 100 000
III more than 100 000 60 15 000 30 000 15 000 30 000

Change the oil with the engine off but still warm (lube oil temperature approx. 80 °C).
1)
Lube oils having both a C- and an S classification (e.g. CD / SE) can be used. Oils with only a C classification
(e.g. CE) generally perform very well in diesel engines and are to be preferred.
2)
D5 grade oil with sulfate ash content > 1.8% by mass.
● In the case of fuels containing more than 1% sul- 3)
SHPD lube oils can be used.
fur, contact your service representative. These are the equivalent of D5 grade.
 6.1 Lubrication System Service and Maintenance

6.1.2 Checking Oil Level / Changing

Engine Oil 6
6.1.2.1 Checking Oil Level 6.1.2.2 Changing the Engine Oil

25729 0 26022 0 26023 0

● Check the oil level with the engine switched off. ● Allow the engine to warm up. ● Place oil tray under the engine.
● Ensure that the engine or vehicle is in a level ● Ensure that the engine or vehicle is on a level ● Unscrew drain plug.
position. position. ● Drain oil.
● Remove the oil dipstick. - Lube oil temperature approx. 80 °C. ● Fit oil drain plug with the new gasket and tighten
● Wipe the dipstick with a non-fibrous,clean cloth ● Turn the engine off. firmly (for torque see 9.2).
● Insert it to the stop and remove again. ● Pour in lube oil
● Check the oil level, and if necessary, top up to - For grade / viscosity, see 4.1.
the "MAX" mark. If the oil level is only just above - For quantity see 9.1.
the "MIN" mark, more oil must be added. ● Check the oil level, see 6.1.2.1

! Be careful when draining hot oil -

danger of scalds!

The oil level must not drop below the "MIN" mark
! Do not let used oil run into the soil
but catch it in a container ready for
proper disposal!

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 Service and Maintenance 6.1 Lubrication System

6.1.3 Changing Oil Filter

6

25880 0 25881 0 25882 0

● Undo the filter cartridge using a commercial tool ● Clean any dirt from the filter carrier rim. ● Tighten the oil filter cartridge with another half-
and spin off. turn.
● Lightly oil the rubber gasket of the new oil filter
● Catch any dripping oil. cartridge. ● Check oil level, see 6.1.2.

● Screw in the new cartridge finger tight against ● Check oil pressure, see 3.3.1.
the gasket.
● Check cartridge seal for leaks.

Beware of burns from hot oil.

!
 6.2 Fuel System Service and Maintenance

6.2.1 Changing Fuel Filter

6

25880 0 25881 0 25882 0

● Close fuel stopcock. smoke. the gasket.

● Clean any dirt from the filter cartridge with a final ● Tighten the fuel filter cartridge with a final half-
● Undo fuel filter cartridge with commercial tool half-turn. turn.
and spin off.
● Apply light film of oil or diesel fuel to the rubber ● Open fuel stopcock.
● Catch any fuel. gasket of the new fuel filter cartridge.
● Check for leaks.
● Screw in the new cartridge finger tight against

Keep naked flames away when work-

ing on the fuel system. Do not The fuel system does not need to be bled.
!
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 Service and Maintenance 6.2 Fuel System

6.2.2 Fuel Pump 6.2.3 Change Fuel Leakage Line

6 Cleaning the Strainer

1 2 4 3

2 3

26 436 0 30 015 0

● Close the fuel shut-off valve. ● Mount the fuel strainer cover 2. ● Close the fuel shutoff valve.
● Loosen and unscrew the hexagonal nut 1. ● Tighten the hexagonal screw 1. ● Disconnect rubber hoses 3 from the injection
● Remove the fuel strainer cover 2 (cover and ● Check for leaks. valves.
strainer, one unit) ● Disconnect rubber hose 1 from fuel tank.
● Clean the fuel strainer with diesel fuel. Replace if ● Disconnect rubber hoses 4, 3 and 1 from unions
necessary. 2 and dispose of in an environmentally friendly
● Place seals 3 in position. manner.
● Connect new rubber hoses 4, 3 and 1 to unions
2.
● Connect rubber hoses 3 to injection valves.
● Connect rubber hose 1 to fuel tank.
● Open fuel shutoff valve.
Keep naked flames away when work- ● Check for leaks after start-up.
ing on the fuel system.
! Do not smoke!
 6.3 Cooling System Service and Maintenance

6.3.1 Cleaning Intervals

6
● The amount of contamination in the cooling
system depends on the engine application.
Inspection and cleaning
intervals
● Spilled oil or fuel on the engine increases the risk Engine application
of contamination. Be especially careful if the Recommended
engine is used in dusty environments. OH
● Serious contamination can occur, for example: 2000 Ships, Electrical units in enclosed areas, pumps
– on construction sites where there is a high
level of air-borne dust. 1000 Vehicles on reinforced highways
– in harvesting application where there are 500 Tractors, fork-lift trucks, mobile electrical units
high concentrations of chaff and chopped
straw in the vicinity of the machine. Vehicles on construction sites and on roads with loose surfaces,
250
construction machinery, compressors, mining equipment
● Because applications vary, cleaning intervals
have to be determined from case to case. The 125 Agricultural machinery, tractors used for harvesting purposes
cleaning intervals given in the table on the right
can be used as a guide.

● Clean the engine as described in 6.8.1.

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 Service and Maintenance 6.4 Combustion Air Filter

6.4.1 Cleaning Intervals

6
● The amount of dirt in the air cleaner depends on
the amount of dust in the air and the size of the
air cleaner used. If a high level of dust is antici-
pated, a cyclone-type precleaner can be fitted to
the air cleaner.

● Cleaning intervals will have to be determined

from case to case.

● Air cleaner servicing is needed when:

– Service indicator
the red signal 1 is fully visible when the
engine is off.
– Service switch
the yellow pilot light comes on when the
engine is running.
25 885 1
● After carrying out service work, reset the signal
by pressing the button on the service indicator.

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 6.4 Combustion Air Filter Service and Maintenance

6.4.2 Emptying Cyclone Type 6.4.3 Cleaning Oil Bath Air Cleaner
Precleaner
6

25 886 0 25 887 1

● Undo wing nut 1 and remove cover 2. ● Turn engine off and wait about 10 minutes for the ● Clean filter housing 1 if very dirty.
● Remove collector bowl 3 from lower section 4 oil to drain from filter housing 1. ● Inspect and replace rubber gasket 5 and 6 if
and empty. Clean leaves, straw and other foreign ● Release snap clips 2 and remove oil cup 3 necessary.
matter from lower section of precleaner. together with filter element 4. If necessary prise ● Fill oil cup with engine oil up to the mark (arrow)
● Reposition collector bowl 3 onto lower section 4, element out with a screwdriver, taking care not to (for viscosity, see 4.1.2).
fasten cover 2 in place by tightening wing nut 1. damage the rubber gasket 5. ● Refit oil cup and element to filter housing and
● Remove dirty oil and sludge. Clean oil cup. secure with snap clips.
● Clean filter element 4 in diesel fuel and allow to
drip-dry.

Never clean air cleaner with gaso-

line. Dispose of cold oil in accord-
Never fill collector bowl with oil. Replace collector
bowl if damaged.
! ance with environmental regula-
tions!

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 Service and Maintenance 6.4 Combustion Air Cleaner

6.4.4 Dry Type Air Cleaner

6 Dust Discharge Valve Filter Cartridge

25 888 1 25 889 0

● Empty dust discharge valve 1 by pressing apart ● Undo clip fasteners 1. ● After five cleaner services or after two years at
lips of discharge slot as indicated by arrows. ● Take off hood 2 and remove cartridge 3. the latest, replace safety cartridge 4 (never clean).
● Clean discharge slot from time to time. ● Clean cartridge (replace at least once a year) To do so:
● Remove any caked dirt by pressing together the ● Clean cartridge 3. – Undo hex. nut 5 and remove cartridge 4.
upper section of the valve. Blow out from inside out with dry compressed – Install new cartridge, insert and tighten hex
air (max. 5 bar), (or in difficult cases, tap out, nut.
taking care not to damage the cartridge, or wash ● Install cartridge 3, replace hood 2 and do up clip
according to manufacturer’s instructions). fasteners 1.
● Through regular removal and replacement, the
gaskets on the filter cartridge can become dam-
aged. Check paper filter (light showing through)
and gaskets for damage. Replace if necessary.
Never clean filter cartridge with
gasoline or hot fluids.
!

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 6.5 Belt Drives Service and Maintenance

6.5.1 Checking V-Belts

6

26 427 0 26 261 0

● Inspect entire V-belt for damage. – Carefully remove the gauge without alter-
● Replace damaged V-belts. ing the position of the indicator arm 1.
● After installing new belts, run engine for 15 – Read off the value where the black indicator
minutes, then check belt tension. arm 1 intersects scale 5 (arrow). For set-
● To check the tension of the V-belt, use a tension tings, see 9.1.
gauge (see 9.3). – If necessary, retension belt and measure
– Place indicator arm 1 into gauge. again.
– Position gauge on V-belt 2, midway be-
tween the pulleys, with flange 3 on bottom
of gauge against the edge of belt.
– Push slowly on the black pad 4 at right
angles to belt 2 until the spring is heard or
felt to trigger. Check tension and change belts only
with the engine off. Refit belt guard,
! if provided. When new V-belts are fitted, check the belt tension
after ca. 15 minutes running time.

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 Service and Maintenance 6.5 Belt Drives

6.5.2 Tensioning Alternator Belts 6.5.3 Changing Alternator Belts

6

4 4
1
2
2

1 3

3
26 425 0 26 426 0

● Slacken off bolts 1, 2 and 3. ● Slacken off bolts 1, 2 and 3.

● Adjust alternator 4 in direction of arrow by
● Adjust alternator 4 in direction of arrow by turning bolt 3.
turning bolt 3 until correct belt tension is achieved. ● Remove and replace belt.
● Adjust alternator 4 against the direction of the
● Retighten bolts 1, 2 and 3. arrow by turning bolt 3, until correct belt tension
is achieved.
● Retighten bolts 1, 2 and 3.

Check, tension and change belts

only with the engine off. Refit belt
! guard, if provided.

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 Service and Maintenance

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 Service and Maintenance 6.6 Adjustments

6.6.1 Checking / Adjusting Valve

6 Clearances

19 691 2 25 893 0

● Remove the cylinder head cover. ● Adjust valve clearance if necessary:

● Position crankshaft as per schematic 6.6.1.1. – Release locknut 4.
● Before adjusting valve clearance, allow engine to – Use allen key 7 to turn setscrew 5 so that
cool down for at least 30 minutes. The oil tem- the correct clearance is attained after locknut
perature should be below 80 °C. 4 has been tightened.
● Check valve clearance 1 between rocker arm / ● Check and adjust valve clearance on all remain-
tappet contact face 2 and valve stem 3 with feeler ing cylinders.
gauge 6 (there should be only slight resistance ● Replace cylinder head cover (use new gasket if
when feeler blade is inserted). needed).
For permissible valve clearance, see 9.1.

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 6.6 Adjustments Service and Maintenance

6.6.1.1 Valve Clearance Adjustments

Schematic
6
● Crankshaft Position 1:
1 Turn crankshaft until both valves in cylinder 1
overlap (exhaust valve about to close, inlet valve
about to open). Adjust clearance of valves marked
in black on schematic. Mark respective rocker
1 2 1 2 3 1 2 3 4 arm with chalk to show that adjustment has been
done.

2 ● Crankshaft Position 2:
Turn crankshaft one full revolution (360°).
Adjust clearance of valves marked in black on
schematic.
1 2 1 2 3 1 2 3 4

25 894 4

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 Service and Maintenance 6.7 Accessories

6.7.1 Battery
6 6.7.1.1 Checking Battery and Cable 6.7.1.2 Checking Electrolyte Level 6.7.1.3 Checking Electrolyte
Connectors Density

25 895 0 24 232 3 25 896 0

● Keep battery clean and dry. ● Remove caps 1. ● Measure the electrolyte density of individual
● Undo dirty clamps. ● If testers 2 are used, the electrolyte should come cells with a commercial hydrometer.
● Clean terminal posts (+ and -) and clamps of the up to their base.
battery, and grease with acid-free and acid- ● If testers are not used, the electrolyte level should The hydrometer reading (see table on following
resistant grease. be 10-15 mm above the top of the plates. page) indicates the state of charge.
● When reassembling, ensure that clamps make ● If necessary, top up with distilled water. During measurement, the temperature of the
good contact. Do up clamp bolts finger tight. ● Replace caps. electrolyte should preferably be 20 °C.

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 6.7 Accessories Service and Maintenance

6
Electrolyte density
in kg/l in ° Bé (Baumégrad)*
State of Charge
Normal Tropics Normal Tropics
1.28 1.23 32 27 Fully charged
1.20 1.12 24 16 Half charged, recharge
1.12 1.08 16 11 Discharged, recharge immediately

* Measurement of electrolyte density in ° Bé

(Baumé-grad) is out of date and rarely used
today.

The gases emitted by the battery

are explosive! Keep sparks and na-
! ked flames away from the battery.
Do not allow battery acid to come
into contact with skin or clothing.
Wear protective goggles. Do not rest tools on the
battery.

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 Service and Maintenance 6.7 Accessories

6.7.2 Three-Phase Alternator 6.7.3 Lifting Tackle

6
Notes on the three-phase system:
● Never disconnect the cables between battery,
alternator and regulator while the engine is run-
ning.
● If, however, it is necessary to start and operate
the engine without the battery, disconnect the
regulator from the alternator before starting.
● Be sure not to confuse the battery terminals. 2 1
● Replace defective bulb of the charge pilot lamp
immediately.
● When washing the engine, cover up the alterna-
tor and regulator.
● The habit of touching a lead against the frame to
check whether it is live must under no circum-
stances be used with three-phase electrical sys-
tems.
● In case of electric welding, connect the ground 26 434 0 26 435 0
terminal on the welder directly to the piece being
welded. ● Always use proper lifting tackle 1 when trans-
porting the engine.
● After transportation and before commissioning
of the engine:
Remove attachment eyes 2.

Use only the correct lifting tackle.

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 6.7 Accessories Service and Maintenance

6.7.4 Ether Starting System

6.7.4.1 Changing the Fluid Container 6

25 965 0 25 956 0

● Before removing the container, clean the con- ● Place the container 1 on the solenoid valve 2 and
tainer support and the top of the solenoid valve. tighten by hand.
● Loosen the bracket 1. ● When mounting, ensure that gasket 3 is seated
● Unscrew the fluid container 2. correctly.
● Empty or replace the depressurized fluid con- ● Pull in the brackets.
tainer. ● Check for leaks.

Before commissioning, leave the

fluid container of the ether starting
! system in position for 15 minutes.
Check for leaks. The starting fluid is
inflammable. Ensure that the con-
tainer is not damaged. Prevent foreign substances
from entering the container. The fluid container
must not be stored at temperatures above 50 °C.

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 Service and Maintenance 6.8 Engine Cleaning

6.8.1 Engine Cleaning

6
Preparation
● Switch off the engine.
● Remove engine covers and cooling air hood.
Replace them after cleaning and before the test
run.
● Cover electrical / electronic components / con-
nections (eg. generator, starter, governor, sole-
noid).
Using compressed air
● Blow air through the engine, taking particular
care not to damage the cooler and cooling fins
(begin to blow through air from the exhaust
side).
Remove the dirt which has blown into the inte-
rior space.
Using cold-cleaning compound
● Spray the engine with the commercial cold-
cleaning compound and allow to react for approx.
10 mins.
● Spray clean the engine with a strong water jet,
repeat if necessary.
● Allow the engine to run up so that the remaining
water evaporates.

Using high pressure device

● Clean the engine with a steam jet (max. spray
pressure
of 60 bar, max. steam temperature of 90ºC).
● Allow the engine to run up so that the remaining
water evaporates.

Clean the engine only when the

! engine is switched off.

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