Mercedes 416 1976 User Manual

Instruction Manual

UNIMDI 416

IW:ERCEDES-DENZ

Instruction Manual

UNIMDIi 416

Edition June 1976

Printed in Germany Technical details of UNIMOG in relation to

data and illustrations of the present manual subject to change.

Reprints and translations, including extracts, subject to our written permission.

Daimler-Benz Aktiengesellschaft Stuttg art-UntertUrkhei m Plant Gaggenau, Department UKD 7560 Gaggenau

P. O. Box 1220 Federal Republic of Germany

Contents

1 General Hints. . . .

Explanation of Contents. . . .. 8

Type Plate and Numbers. . . .. 8

Keys. . . . . . . . . . . . . . 10

Doors, Seats and Tools. . . . . . 10

2 Operating Instructions

. . . . 11

Instruments and Controls. . . . . 11

Instrument Panel. . . . . . . . 11

Shifting Levers. . . . . . . . . 12

Switches. . . . . . . . . . . . 13

Putting Vehicle into Operation. . 14 Preparations Before Starting. . . 14

Starting the Engine. . . . . . . 14

Running-in. . . . . . . . . . . 15

Stationary Operation. . . . . . . 15

Stopping the Engine. . . . . . . 15

Transmission Shifting. . . . . . 15

Special Drive for pto Shift. . . . 16

Four-Wheel Drive, Differential Locks 16

Instruments, Warning Lights. . . 16

Brake System. . . . . . . . . . 16

3 Maintenance Instructions. . . 17

Maintenance. . . . . . . . . . 17

General. . . . . . . . . . . . 17

Maintenance Schedule. . . . . . 17

Maintenance Jobs Survey. . . . . 18

Lubrication Points Survey. . . . . 19

Engine. . . . . . . . . . . . . 20

Filling-up Engine Oil. . . . . . . 20

Oil Level and Oil Change - . . . . 20

Cleaning Oil Filter -

. . . . . . . 21

Oil Overpressure. . . . . . . . 21

Retightening Cylinder Head Bolts. 21

Replacing Cylinder Head Gasket. 22 Adjusting Valve Clearances. . - . 22

Checking Compression Over-

pressures. . . . . . . . . . . . 23

Air Filter. . . . . . . . . . . . 23

Fuel. . . . . . . . . . . . . . 24

Filling-up Fuel. . . . . . . . . . 24

Cleaning Fuel Tank. . . . . . . 24

Cleaning Fuel Prefilter. . . . . . 24

Cleaning Fuel Filter. . . . . . . 25

Priming and

Feed Pump. . . . . 26

Bleeding Fuel Filter. . . . . . . 26

Bleeding Fuel System. . . . . . 26

Checking and Cleaning Injectors. . 26

Cooling System. . . . . . . . . 27

Filling-up Coolant. . . . . . . . 27

Coolant Pump. . . . . . . . . . 28

. . . . 28

. .. . 28

System - . . . 29

. . . . . . . . . 29

Thermostat. . . . . . .

Draining Coolant Cleaning Cooling

Coolant Hoses

Clutch, Transmission, Axles. . . . 29

Clutch - . . . . . . . . . . . . 29

Transmission. . . . . . . . . . 30

Axle Drive. . . . . . . . . . . 31

Hub Reduction. . . . . . . . . 31

Steering Knuckle Bearings. . . . 31

Steering. . - . . . . . . . . . 32

Checking Steering. . . . . . . . 32

Oil Level, Oil Change, Oil Filter. . 32

Bleeding Power Steering. . . . . 32

Power Steering Pump V-Belt. . . 32

Wheels, Tyres . . . . . . . . . .

Wheels. . . . . . . . . . . . .

Check toe-in . . . . . . . . . . 33

Tyres

.,...........

reTres...........

Checking Tre Overpressure. . . .

Grip and Traction. . . . . . . .

Care of Wheels and Tyres . . . .

Install Spare Tyre . . . . . . . .

BrakeSystem. . . . . . . . . . 35

General. . . . . . . . . . . . 35

Filling-upBrakeFluid. . . . . . . 35

BleedingHydraulicBrakeSystem. 35

Checkingand CleaningBrakes. . 36

ReadjustingBrakeShoes. . . . . 36

Adjusting Brake Pedal. . . . . . 37

Readjusting Parking Brake System 37

Leversand Pedals. . . . . . . . 37

Brake Hoses,Brake Lines. . . . 37

CompressedAirSystem. . . . . 38

General. . . . . . . . . . . . 38

Air Compressor. . . . . . . . . 39

Pressure Regulator, Inflating Tyres 39

Compressed Air Tank. . . . . . 39

Compressed Air Brake Assistance 39 Compressed Air Operated Differen-

tial Locks. . . . . . . . . . 40/41

Chassis,Body. . . . . . . . . 48

BoltedConnections. . . . . . . 48

ShockAbsorber,Trailer Coupling. 48

Tilting Driver's Cab. . . . . . 48/49

Folding Top. . . . . . . . . . 50

Windscreen. . . . . . . . . . . 50

Canvas. . . . . . . . . . . . . 51

Tow-Bar. . . . . . . . . . . . 51

Benches. . . . . . . . . . . . 52

Cleaning. . . . . . . . . . . . 53

CleaningCanvas. . . . . . . . 53

CleaningUNIMOG. . . . . . . . 53

Laying-upUNIMOG. . . . . . . 53

Putting into Operation after Laying-

upPeriod. . . . . . . . . . . . 54

Winch. . . . . . . . . . . . . 54

WinchMounting. . . . . . . . . 54

PtoShaft. . . . . . . . . . . . 54

BrakeFluid. . . . . . . . . . . 56

TransmissionOil. . . . . . . . . 56

Grease. . . . . . . . . . . . . 56

Anti-corrosiveOil. . . . . . . . 56

5 TroubleShooting. . . . . . . 57

General . . . . . . . . 57

Towing. . . . . . . . . . . . . 57

EngineGroup. . . . . . . . . . 57

EngineFailsto Start. . . . . . . 57

Engine Difficult to Start. . . . . 58

EngineBeginsto KnockHeavily. . 58

Engine Emits Black Smoke. . . . 58

Poor Engine Performance. . . . 59

ExcessiveCoolantTemperature. . 59

Oil Overpressure Drops Suddenly 60

Clutch. . . . . . . . . . . . . 60

ClutchDisengagesInsufficiently. . 60

ClutchSlips. . . . . . . . . . 60

SteeringSystem. . . . . . . . . 61

Intermittent Stiffness of Power

Steering. . . . . . . . . . . . 61

Power Steering Stiff. . . . . . . 61

Directional Stability of UNIMOGin Straightahead Position Unsatis-

factory. . . . . . . . . . . . . 61

Electrical System

. . . . . . . .

General .........,..

Operative Materials. . . . . .

Three-PhaseAlternator. . . . . .

Regulator

Filling Capacities

. . . . . . . . 55

. . . . . . . . . . .

Starter. . . . . . . . . . . . .

ConsumptionValues. . . . . . .

Wiring Diagram

. . . . . . . 43/44/45

Coolant.............

Checking Battery

. . . . . . . . 46

Coolant for Operation

. . . . . .

COnnectingBattery

. . . . . . .

HeadlightAlignment. . . . . . .

EngineOil

. . . . . . . . . . . 56

Replacing Headlight Bulb

. . . .

Running-in Oil

.. . . . . ..

{)

AlternatorV-Belt. . . . . . . . .

Heavy-dutyOil

. . . . . . . . .

Brake System. . . . . . . . . . 62

WheelBrakes. . . . . . . . . . 62

HydraulicBrake System. . . . . 62

CompressedAir Brake Assistance

System. . . . . . . . . . . . . 63

CompressedAir System. . . . . 63

Warning Light Lights up While

Driving. . . . . . . . . . . . . 63

Insufficient or too Slow Over-

pressure Build-up. . . . . . . . 63

Dual Overpressure Gauge Indicates

Incorrectly. . . . . . . . . . . 64

Air Compressor. . . . . . . . . 64

PressureRegulator. . . . . . . 64

ElectricalSystem. . . . . . . . 64

ChargingCurrentWarning Light

Doesnot Light up . . . . . . . . 64

Charging Current Warning Light

Lightsup while Driving. . . . . . 64

StarterMotor Doesnot Operate. . 65

Current ConsumerInoperative. . 65

lnefficient Headlights. . . . . . 66

Direction Indicator System. . . . 66

6 Technical Data

. . . . 67

TypesandModels. . . . . . . . 67

Engine. . . . . .

. . . 67

Clutch,Transmission,Axles. . . . 68

Clutch. . . . . . . . . . . . . 68

Transmission. . . . . . . . . . 69

Front Axle. . . . . . . . . . . 69

RearAxle. . . . . . . . . . . . 69

Steering. . . . . . . . . . . . 69

Powersteering. . . . . . . . . 69

Tyre . . . . . . . . . . . . . . 70

TyreTreads. . . . . . . . . . . 70

Tyre Overpressures. . . . . . . 70

Toe-in. . . . . . . . . . . . . 69

BrakeSystem. . . . . . .

Hydraulic Brake System. .

Parking BrakeSystem. . . .

BrakeAssistanceSystem

. . . 71

. . 71 . . 71

. 71

Electrical System. . . . . . . . 71

PtoShaft. . . . . . . . . . . . 72

Weight. . . . . . . . . . . . . 72

Dimensions. . . . . . . . . . . 73

Max.Speed. . . . . . . . . . . 73

Tightening Torque

. . . . . . . 74

V-Belts. . . . . . . . . . . . . 75

1 General Hints

Explanation of Contents

In addition to general explanations, this section 1 General Hints also contains

important details with regard to per-

tinent numbers, keys and equipment of

the UNIMOG.

A careful study of section 2 Operating

Instructions in particular prior to initial operation, is one of the prerequisites for

troublefree operation of the UNIMOG.

In addition, relevant instructions in sec-

tion 3 Maintenance Instructions are

intended to guarantee that the UNIMOG remains efficient and constantly avail-

able for use.

Use only the types of fuels, lubricants, coolants, etc. described in section 4 Operative Materials in the quantities specified.

In the following section 5 Trouble Shoot-

ing we are providing remedies and refer-

ences as to their possible cause, as well as recommendations for their

repair.

For fast information, all the significant

dimensional data concerning the eng;ne, the chassis and the body are listed in

section 6 Technical Data.

Type Plate and Numbers

In all inquiries concerning the UNIMOG, and when ordering spare parts and special equipment, be sure to name the type and model designation, chassis and engjne number, as well as any other

unit number.

The type plate is located above the

right-hand foot compartment underneath

the outside hood.

The chassis number is on the type plate and on the frame at the right front in front of the spring bracket.

The engine number plate is located on the right rear next to the oil filter and on the cylinder head cover.

The designations "right-hand" and "Ieft- hand" apply as seen in driving direction.

The statements 1st, 2nd cylinder, etc. are always as seen from the direction

of the radiator.

1 Chassis number

2 Type plate 3 Transmission number

4 Cab number 5 Engine number

6 Axle Number

Fig.1 Arrangement of type plate and numbers

URO-OOO6

Fig. 2 Door locks

1 Driving position (latched) 2 Garage position 3 Open

Fig. 3 Vehicle tool box under

co-driver's seat

Fig. 4 Seat adjustment

1 Longitudinal adjustment 2 Tilt of seat cushion

3 Tilt of backrest

Keys

The switchbox key serves for switching

the switch box in the instrument panel.

The square drive bonnet key is in the

left-hand door box. It is used for opening

the bonnet.

Doors, Seats and Tools

The door locks of the folding top cab

must be latched from inside while driv- ing. In latched condition the inside door

latch is positioned at an upward angle. The door can be locked only when in this position.

For seat adjustment refer to Fig. 4.

For tools refer to Fig. 3.

2 Operating Instructions

Fig.5

Arrangement of instruments

and controls

8 Hand throttle 9 Accelerator pedal

10 Brake pedal

11 Clutch pedal

12 Parking brake lever 13 Socket for emergency light

1 Starter switch 2 Windshield wiper switch

3 Switch box 4 Blinker - Horn - Dimmer switch lever

5 Spedometer 6 Cut-out switch for blinker

7 Instrument cluster

Fig.6

Instrument cluster

1 Brake overpressure warning light (red) 2 Blinker control light UNIMOG (green) 3 Oil overpressure indicator

4 High beam control light (blue)

5 Fuel gauge

6 Charging current control light (red)

7 Dual brake overpressure gauge

White needle ~ tank overpressure

Red needle ~ brake overpressure 8 Coolant temperature gauge 9 Blinker control light for 2nd trailer (green)

Fig.7 Shifting levers

1 Main shifl lever

2 Forward-reverse levar

3 High-low range lever 4 Four wheel drive/differential lock lever

5 Plo-shifl lever

Transmission with 2 x 4 gear shifting

Shifting position 2 x 4

'H3

I .v

2 4

I 00

3 2

Shifting I

Shifting position

lever

Main shifting lever

1-4

1s1 10 41h gear

Forward-reverse shifting lever

Forward gears

Neulral position

Reverse gears

High-low range shifting lever

GV+R

Low range forward and reverse

High range forward

4 Four-wheel drive-ditto lock

Rear axle drive

shifting lever

VA Four-wheel drive VA+AS Four-wheel drive and difl. lock

Plo shifling lever

Engaged

Disengaged

Switch, Explanation

Switch _

Positions

Consumer

Off Socket, interior light

Parking position

Parking, Clearance light

Instrument cluster light

Socket

Drive position

Charging current control light

Starter switch Horn, socket, interior light

Blinker-tail-stop light

Windshield wiper

Instrument indicator

to 1, additional

Parking, Clearance light Instrument cluster light

to 1 and 2, additional

Headlight low beam

Headlight high beam High beam control light

* To switchinq from "0" to "P"

and from "3" to "2" push ignition key down.

Switches

UZ54-0025

Fig. 8 Switch box

Fig. 9 Blinker-Horn-dimmer switch

1 High beam

2 Low beam 3 Blinker light right

4 Blinker light left 5 Horn

Putting UNIMOG into

Operation

Preparations

before Starting

Check coolant level in compensation

tank. Actuate push button of safety valve

prior to opening closing cap to relieve any excess pressure.

The coolant of the cold engine should

be up to 30 mm below the upper edge of the filler hole of the compensation

tank. Add coolant, if required.

Be sure to add 10 cc of inti-corrosive

agent for each liter of coolant.

Fig.10 Coolant compensation tank

1 Closing cover with safety valve 2 Overflow line

Run engine for 5 minutes at increased idling speed. If required, add coolant

with the engine running, until cooling

liquid level is reached.

Check oil level in oil pan with wiped- off oil dipstick with the UNIMOG on level ground. The oil level should be on

the maximum level mark. When checking the oil level of the engine be sure to consider that the oil cooler and various

oil passages can be completely drain- ed when the engine has been inopera-

tive for some time. To determine the

exact oil level in the oil pan it is neces- sary that the check is conducted imme-

diately after shutting off the warm engine

or after a short running period of the

previously cold engine.

Do not fill up beyond the maximum level mark!

Check contents of fuel tank.

Check tyre pressure. Check lights.

Test brakes after moving off. Important

Move vehicle only after red light on instrument cluster is gone off.

Starting the Engine

Move main shift lever and hand throttle into center position (idling speed).

Insert switch box key into switch box

and turn to position 1:

Red charging current control lamp lights up and fuel gauge responds.

Declutch and step on accelerator pedal.

Push starter switch and hold for some

seconds. Engine will fire. Release star~

switch immediately after engine fires since this can otherwise cause damage to the starter.

If the engine does not fire immediately,

repeat starting attempt only when the

engine and the starter have come to

a stop. During repeated starting attempts

short recovery periods for cooling the

starter and conserving the battery

should be imposed.

Watch oil pressure gauge after engine

fires.

If no oil pressure is indicated with the engine running, stop engine immedia- tely and look for the cause.

Adjust idling position with hand throttle

until the engine runs "smoothly" at slightly increased idling speed.

Running-in

It is of decisive importance for the life

and the operational safety that the engine and drive train of a new UNI-

MOG, an exchange engine or recon-

ditioned engine are not fully exploited

during the first 1500 km.

Complete the specified service jobs according to schedule once during the

running-in time up to 500 km. The regu- lar service jobs according to schedules

will then begin. Page 17.

Stationary Operation

For stationary operation of the pto shaft and low-speed operation the desired engine speed can be fixed by means of the hand throttle control. Tighten round locking disc in clockwise direction.

While operating the pto drive stationary make sure that the low range/high range lever is in "high range" to guarantee the oil supply to all rotating

parts inside the transmission.

Stopping the Engine Pull hand throttle control toward the

rear and turn completely to the right. Engine will stop. Immediately turn hand

throttle control back to idle position. At

a coolant temperature of 90 to 95° C do

I \

I,.A<,

,,'

"'-,

( I

"J.,.J

"-""../

UZ 30-0001

Fig. 11 Hand throttle control

1 Full throttle position

2 Idle position 3 Stop position 4 Locking plate

not stop the engine immediately but

keep it running at increased idling speed for 1 or 2 minutes, so that the coolant remains in circulation and is

not thrown out by the reheating effect

of the engine.

Transmission Shifting

2 x 4 Shifting

The manual synchromesh transmission

has 4 forward low range gears, 4 forward

high range gears and 4 reverse gears.

The 4 forward low range gears have

been provided for increased traction.

They are shifted with the low range/hi!;lh

range lever (3) after disengaging the

clutch. Page 12.

For road operation, the 4 forward high range gears are sufficient, i. e. start the

vehicle, depending on trailer weight,

with the 1st high range gear engaged.

For reverse operation, declutch and move the short forward/reverse lever to

the" reverse" position, the UNIMOG

being stationary.

For repeated forward and reverse ope- ration, keep main shift lever in its posi-

tion and shift to forward and reverse only with the short forward/reverse lever.

See page 12.

Special Drive for pto Shaft

A special drive for pto shaft of 1/min,

540 can be installed.

The rotation of pto shaft will stop dur-

ing declutching.

Four-Wheel Drive, Differential

Locks

If under difficult ground conditions or

with a high total train weight the ground adhesion of the rear wheels is inade-

quate, engage the four-wheel drive or

the four-wheel drive with differential

locks. This will provide high tractive power for the UNIMOG in sprre. ot.-its low dead weight. Putting an additional load on the platform may improve ground adhesion still further.

The four-wheel drive and the differential

locks can be engaged while driving

without declutching, but only when the

wheels are not spinning, that is, as long

as the wheels are rotating in contact

with the ground.

If a wheel slips when the four-wheel

drive or the differential locks are

engaged, declutching is required so that all the wheels are turning at uniform speed or that the UNIMOG comes to a

stop.

The differential locks and the four-wheel drive can also be disengaged while

driving without declutching. Briefly

release accelerator pedal when disen- gaging the four-wheel drive.

Try not to engage the differential locks when driving around a road bend to

eliminate additional stresses.

With the differential locks engaged the turning circle increases as a result of the automatically resulting wheel slip.

Instruments, Warning Lights

Check instruments" warning and control lights occasionally while driving. The most favorable operating temperature of the coolant is at approximately 80° C

and is indicated on the coolant tempera- ture gauge. At this temperature the engine wear and the fuel consumption

are the lowest. If possible, the operating temperature should not exceed 95° C.

Brake System

Test brakes immediately after moving

off. Establish braking action on a dry road affording good grip.

The hand brake system serves as an

auxiliary and a parking brake system acting on the rear wheels only.

3 Maintenance Instructions

Maintenance

General

The maintenance jobs specified for the

UNIMOG are specified in the Service Booklet.

When driven on roads the maintenance intervals are subdivided according to

km.

If, for organizational reasons, the main-

tenance jobs have to be accomplished

by your own personnel we urgenlly recommend adherence to the required

maintenance procedures.

Thoroughly clean grease nipples, oil filler and drain plugs prior to lubrication jobs.

Maintenance Schedule

jkm

Job schedule

Job accomplishment

Maintenance

interval

500

* Only once during running-in period of vehicle

Normal

operating conditions

1000

2000

3000 4000 5000

6000 7000 8000

etc.

* Lubrication jobs:

Change engine oil Replace bypass oil filter element Change transmission oil Change oil in differential (2)

Change oil in wheel hub drive (4) Check oil level in steering Check brake fiuid level

Lubricate thrust ball (2)

Lubricate steering knuckle bearings (4)

Lubricate clutch release. shaft

Lubricate pto shaft universais (2)

Lubricatetrailer coupling (2)

Lubricate intermediate hand brake lever

* Inspection and cleaning jobs: Clean dry air filter element

Retighten cylinder head nuts

Check valve clearance, adjust Retighten air intake-manifold and oil pan mounting screws

Check V-belt Check clutch play Retighten stabilizer bar/drive units mounting-

and connecting

screws Check pHman arm for tight seat, steering for correct functioning

Check wheel nuts

Check brake system

}

1stT.M.

2nd T.M.

Referto Maintenance

}

Lubrication Points

1stT.M.

Survey

2nd T.M. etc.

Maintenance Job Survey

Inspection and cleaning jobs

Pos. Nr.

daily

1st TM 2nd TM

Engine Check engine oil

Clean air filter element Check valve clearance, adjust Clean fuel pre-filter

Retighten suction-Iexhaust- and

oilpan mounting screws

Cooling water

Check V-belt, retighten

Clean fuel fiIter felt element, paper

filter element must be changed, bleed

Chassis

Check clutch adjustment

Check differential locks for

functioning

Retighten stabilizer, drive train

fastening and connecting bolts

Check shock absorbers for leaks

Check brake- and clutch fluid Check pitman arm for tight seat

steering for free travel, correct

Check toe-in

Interchange wheels

Retighten wheel nuts Check brakes, adjust Check compressed air system for

functioning and leaks, drain conden- sation from compressed air tank and differential lock

Electrical system

Check all current consumers, fuses

and line connections Check battery Check head light alignement, correct

Check all electrical instruments

Body

Check bolts of cab and body attach-

ment for tight seat, retighten

14 15

2 5

- = work to be performed

Lubrication jobs

Pos.

No.

Oil

Lub. Grease daily

Points Qly.

1st TM 2nd TM

x = Check xx = Lubricate

v ~ Change oil

Engine 011:SAE 20 or SAE 30

Change oil in engine,

change oil filter

1+3

10.0

x v

Change oil in air filter

1.0 x

v v

Lubricate starter pinion

5 gr

Transmission 011:SAE 90

Transmission

9 1 6.0 x

Front axle differential 6 1 2.5 x v Rear axle differential

6 1 2.5

K v

Wheel hub drive front 7 2 0.3 x

Wheel hub drive rear

2 0.3 x

Grease: Calcium No.3

Thrust ball front and

rear axle 4

10 gr

xx xx

- Grease clutch shaft 8 1

5 gr

I G"", """"""";00 '"

10 gr

xx xx

Grease front winch 1

10 gr

xx xx

Grease pto shaft universal 13 2

10 gr

xx xx

Grease joints and nipples

on manual and pedal lever assy. door hinges

5 gr

Grease hand brake

intermediate lever

10 1

10 gr

Greease steering knuckles

10 gr

xx xx

Hydraulic 011

Steering *

5 1

2.0

x x

Brake fluid

Check brake- and clutch

fluid level

2 1 1.0

x x x

* Change oil and replace paper oil filter element after the first 52000 km

or once a year.

a Fill-in engine oil

b Fill-in transmission oil

c Check oil level

d Drain oil

e Lubricate with grease

f Replace oil filter element

CDFill-in and check brake fluid

Fig.13 Engine lubrication 1 Oil filter

2 Oil dipstick 3 Oil filler neck 4 Crankcase breather

5 Oil filter filler plug 6 Mounting bolt 7 Oil filter drain plug

UR-0035

Fig.14 Oil drain plug

Engine

Filling-up Engine Oil The oil filler neck is located at the rear

in the cylinder head cover, accessible from the cab after removal of the inside

engine hood. Filling-up may also be ac- complished at the breather neck on the

timing gear case.

Engines of the new UNIMOG, exchange engines and fully reconditioned engines are filled with running-in oil for the first

500 km. After this, only HD (heavy-duty) engine

oil grades of the specified viscosity class are permitted. Refer to page 56.

Change HD engine oil brand if at all

possible only during an oil change.

Oil Level and Oil Change Check oil level regularly depending on

the UNIMOG operating conditions and make adjustments, if required.

Check oil level in oil pan with the UNI- MOG on level ground and with the oil dipstick wiped off.

The oil level should be between the minimum and maximum mark.

When checking the oil level of the engine, it must be considered that the 011cooler and various oil passages will drain after not being run for some time.

In order to exactly determine the. oil level in the oil pan, it is necessary that the check be made either immediately after turning off the warm engine, or

after briefly running the previously cold

engine.

If oil must be added already prior to the first oil change and if no running-in oil is available, an HD engine oil of the same viscosity class may be used as an ex-

ception.

Do not add 011beyond the max. level mark!

Complete oil change according to the

maintenance schedule.

Complete oil change only following ex- tended operation of the engine, as long

as the engine oil is still warm and thin.

Change the bypass oil filter element

during every oil change. HD engine oil will become dark sooner than unblended

engine oil, because the combustion

residue entering the oil will not settle in

the crankcase and on crank assembly

components, but will be kept suspended

in the oil. Do not change the HD engine

oil too early because of its dark color.

...

Cleaning Oil Filter

Clean the combination oil filter with

main flow and bypass oil filter element

according to maintenance schedule.

Attach approximately 0.6 m of hose to

the drain connection of oil filter. Place a collecting vessel underneath, loosen

drain plug, unscrew filler plug and drain engine oil.

Loosen mounting bolt of oil filter bowl. Remove filter bowl with filter elements.

Close center hole of main flow oil filter element on both sides, rinse with gaso-

line and then clean with a soft and not

too large a brush, so that the filter fabric

is not damaged. Change bypass oil filter element. When

assembling, place the main flow oil

filter element, the bypass oil filter ele-

mentand the resilient sealing washer on

the oil filter housing.

Replacesealing rings.

To get oil pressure at once during start-

ing procedure, fill-up oil filter bowl half

way. Watch out for correct position of drain

plug screw on oil filter bowl.

Oil Overpressure Under normal operating conditions and

when using engine oil of viscosity class

SAE 30 at nominal speed the oil over- pressure is at least 2.5 bar (kp/cm2). At

idling speed it may drop to 0.6 bar (kp/cm2) without in any way endangering the operational safety of the engine.

.>UR.OO28

Fig.15 Oil filter of engine,

disassembled

1 Oil filter bracket 2 Oil filler plug

3 Seal ring 4 Oil filler housing 5 Drain plug 6 Seal ring

7 Mounting bolt

8 Bypass oil filter element 9 Main flow oil filter element

10 Spring plate

Retightening Cylinder Head Nuts This maintenance job is done only once.

Clean area around cylinder head cover

thoroughly. Remove cylinder head cover

and rocker arm shafts. Should it occa- sionally happen that the cylinder head

cover removal is impeded by the lower

edge of the instrument panel, loosen the

front portion of the cab mounting and

liftthe cab approximately 20 mm. First loosen each individual nut slightly

prior to retightening.

Injection pump side

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Fig.16 Tightening pattern of cylinder

head nuts

Uniformly retighten cylinder head nuts with the engine cold according to tightening pattern with torque wrench to specified torque of 110 NM (11 kpm). Adjust valve clearance Refer to page 67.

Fig.17 Retightening cylinder head nuts

1 Torquewrench

Replacing Cylinder Head Gasket

If a cylinder head gasket leaks combu- stion gases, replace immediately with a new original gasket.

Indications for a damaged gasket may be among others:

Missing of one or several cylinders, tra- ces of water on oil dipstick, traces of oil

in coolant or coolant in compression chamber. Boiling coolant.

To check the cylinder head gasket for

leaks, run engine warm and watch in the

coolant filler neck whether gas bubbles

are rising in the coolant.

Fig.18 Valve adjustment

1 Feeler gauge between rocker arm and valve

stem

2 Adiustment bolt

3 Counter nut

1st cylinder at TDC

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

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UZ 05-0002

6th cylinder at TDC

Fig.19 Valve arrangement

0 Exhaust valves 0 Intake valves

Drain coolant if cylinder head gasket is

damaged, Remove cylinder head cover

and gasket. Unscrew rocker arm bearing brackets. Loosen cylinder head nuts with

the engine cold in reverse to tightening

sequence. Unscrew stud bolts and

remove cylinder head, Clean contact

surfaces of cylinder head gasket. Posi-

tion new cylinder head gasket and cy-

linder head, Screw in stud bolts with

screwdriver; apply graphite oil to threads

of nuts and bolts. Uniformly tighten cy- linder head nuts with engine cold ac- cording to tightening pattern (Fig. 16) with torque wrench in three steps from 60 Nm (6 kpm) via 90 Nm (9 kpm) to the specified torque of 110 (11 kpm). Adjust valve clearance. Complete all other jobs

in reverse sequence.

Adjusting Valve Clearances

Check valve clearance according to

maintenance schedule each time upon removal of cylinder head or when

retightening the cylinder head nuts. Measure valve clearance at pressure point between rocker arm and valve

stem of intake and exhaust valves with

engine cooled down to below 25° C. Rotate crankshaft until the piston of the

1st cylinder is at TDC. Adjust the intake

valves 2, 3, 7 and the exhaust valves 1,

5, 9 in the

sequence mentioned.

Thereafter position the piston of the 6th cylinder at the TDC and adjust the

intake valves 6, 10, 11 and the exhaust

valves 4, 8, 12 in the sequence men- tioned. Fig. 19.

Adjust valve clearance by turning adjustment bolts after lossening their counter nuts with a feeler gauge. Fig. 18.

After adjustment tighten the counter nutsagain. Check valve clearance again.

When the valve clearance is properly

adjusted the feeler gauge should pass

tightly.

Renew cylinder head cover gasket.

Checking Compression Overpressures

Whenthe engine output drops, measure

compression pressure in each cylinder by means of compression pressure gauge. Measure at starter speed of approximately 150 to 200/min and warmed up engine. Crank engine with starter for at least eight rotations.

If the minimum value is not attained,

check valve clearance. If required,

remove cylinder head and check valve

for leaks, condition of cylinder head

gasket, cylinder wear and piston ring

contact pattern in cylinder. Refinish valve seats, if required. Engine

must be reconditioned in the event of

cylinder or piston ring damage.

Air Filter A carefully cleaned air filter is absolutely

necessary to protect the pistons and cy- linder contact surfaces and in order to

avoid damage.

Oil bath air filter

Change oil according to UNIMOG con- ditions of operation.

Loosen quick-release lock for removing

filter bowl on front folding part of fender.

Force filter element and filter bowl from

filter housing with screwdriver. Lift filter element out of filter bowl.

The oil level must be at the appropriate

mark.

Complete oil change according to main- tenance schedule, performing all the specified jobs. Remove oil, clean filter

element and filter bowl with benzene

and fill up with fresh engine oil.

Dust deposits on the clean air en9 and

in the intake manifold are a sure sign that the oil bath air filter must be

cleaned more often than stated in the

maintenance schedule.

Cyclone prefilter

Under extremely dusty operating con-

ditions, we recommend using a cyclone

prefilter in addition to the oil bath air

filter in order to triple the service life of the oil bath air filter.

The cyclone normally requires no main- tenance. Remove the cyclone and thoroughly clean according to type of

dust accumulation.

Fig.20 Oil bath air filter, disassembled

1 Filter bowl 2 Gasket 3 FiIter element 4 Filter housing w. oil level mark (arrow)

Fig. 21 Fuel system of engine

Fig. 22 Injection pump 1 Fuel feed pump

2 Sugtion- and pressure valve 3 Fuel primer pump 4 Bleeding screw

5 Pressure valve

To Fig. 21

1 Injection pump

2 Fuel priming pump

' 3 Fuel feed pump

4 Fuel return line 5 Fuel suction line 6 Fuel filter

i 7 Fuel injection line

Fuel System

Filling-up Fuel

When filling fuel into the fuel tank make

sure to avoid impurities, that the cap gasket is not damaged and seals tightly. Clean cap regularly.

Dirty fuel will result in early wear of the high-grade and very expensive injection pump elements.

When filling up from barrels or call's the following points should be observed:

Always suck fuel from closely under

the fuel level of the barrel, that is, do

not simply set suction pump into barrel. Maintain minimum distance between

bottom of barrel and end of intake pipe, so that deposits such as dirt, sludge

and water will not be sucked in.

Cleaning Fuel Tank Clean the fuel strainer in the fuel tank

regularly. If installed, remove filler strainer after

unscrewing the cap and wash with

brush in diesel fuel. Drain fuel tank completely to clean the

fuel tank and intake strainer. Have

collecting vessel ready for use, unsc"rew drain plug and drain remainder of fuel.

Pull intake strainer from intake pipe and

clean. Fig. 23 and 24.

Cleaning Fuel Prefilter Clean prefilter according to main-

tenance schedule. Loosen wing nut, push

clip aside and remove bowl. Unscrew strainer body. Carefully wash bowl and strainer in clean gasoline or diesel fuel.

During reinstallation replace worn or hardened gaskets since otherwise air

will enter the fuel system. Fig. 25.

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