Mercedes-BenzService

Unimog

WorkshopsManual

UNIMOG421-411

Volume1

U

'DaimlerChrysler

AG,Produktbereich

Sonderfahrzeuge/UnimogD76744

WOrth

SämtticheRechte

derVerbreitung

-injeglicher

Formund

Technikeinschlie8lich

derEinspeicherung

inelektronische

Medien-sind

vorbehalten.

Technicaldetails

ofthevehicle

inrelation

todata

andillustrationscontained

inthismanual

aresubject

tochange.

Allrights,

includingreprint,

reproductionor

translationalso

ofextracts,

reserved.

Buch&Bildhat

1994vom

ProduktbereichUnimog

dasCopyright

fürden

Nachdruckder

technischenUnimog-Oldtimer-Literatur

erhalteri.

WESTFIELD4x4

SparesforMB

UnimogsTel:

+440

1524791968

Fax:+440

1524792653

sa1es@west_4x4.dem0fl.c0.uk

*-.‘s,I-.c._,,.t,‘0

wessel@buchundbild.dewww.buchundbild.de

Anderungenvorbehalten

UND30

4022103

05.89

Introduction

Thepresent

workshopmanual

comprisesthe

descriptions

ofall

importantassembly,

tuning,testing

andreconditioning jobs.

Thecontents

ofthe

workshopmanual

aresubdivided

accordingto

thegroups

knownas

such.The

groupin

dexfacilitates finding

theindividual

groups,the

list ofcontents

ofeach

groupfacilitates

findingthe

individual

jobs.

Thepertinent

data,adjusting

values,dimensions

andtolerances,

aswell

asthe

specialtools,

arelisted

onthe

firstpagesof

therespective

groups.

Thecontents

aredivided

accordingto

unitversions

andsubdivided

accordingto

chaptersand

sections.

Thecontents

arepresented

inthe

shapeof

smaller.individually

completesections.

Eachsection

beginswith

anew

page1and

is identifiedas

followsexample:

Anyreference

tothis

page,at

anyplace

inentire

workshopmanual

says:Refer

to46.1-4.1/1.

Removaland

installationof

steering

Indicationof

page:

Titelof

chapter

4S.1

MB-mechanicalrecirculating

ballsteering

L3,

5K

Unitdesignation

Group

Unit

4.1/11

Introduction

Theunit

versionsare

consecutivelynumbered

starting

at1

*thatis, each

versionhas

itsowncods

num

ber.The

unitdesignation

ofeach

pageisadditionally

placedunder

headof

eachpage.

Aseparating

sheetand

adetailed

list ofcontents

is locatedin

frontof

eachunit.

Thesections

whichare

validfor

allunit

versionsare

coveredin

version0.

Thedata

adjustingdata,

tighteningtorques,

machining

dimensions,etc.

andspecial

toolsare

separatelylisted

infrontof

eachunit

version.

Thenumerical

valuesexpressed

inSI-units

basedon

thenew

internationalunit

systemhave

beenconverted

androunded

offacc.

toDIN

1335.

Thepressure

dataspecified

inbar

aregauge

pressures.

Daimler-BenzAktlenges.llschaft

WerkGaggenau

UNIMOG-Kundendienst

OutputinkW

kilowattFormer

unitHP

horsepower1kW

=1.360HP

1HP

=0.735kW

TorqueinNmnewtonmeter.

Formerunit

kpmkilopondmeter

lNm

=0.lOl972kprn

1kpm

=9.80665Nm

Pressurein

barBar

Formerunit

kp/cm2kilopond

persquare

centimeter1bar

=1.019

716kplcm2

1.020kp/cm2

1kp/cm2

=0.980665

bar0.981

bar

Thespecified

partnumbers,

aswell

asthe

fig.number

inexploded

viewsare

servingonly

foridentification

andbetter

differentiationof

theindividual

versions.When

orderingspare

parts,always

usethe

partnum

bersfrom

validmicrofiches.

Weshall

doour

bestto

keepthisworkshop

manualcontinuously

upto

dateby

meansof

additionalsup

plements.

0.102kpm

981Nm

2

General00

Contents

Chapterpage

1General

421

Installationsurvey

1.1/1

Overallview

1.2/1

Vehicledimensions

1.3/1

Maximumspeeds

1.4/1

Weightsand

trailerloads

1.5/1

Serviceproducts,

capacities1.6/1

2General

Type411

Technicaldata

2.1/1

UKO3040221

03-06

GeneralInformation

00

Installationsurvey

startingchassis

endNo.009854,

Sept.1974

Modeldesignation

VehicleSales

designationWheelbase

421.124/125421.140/141

421.128/129421.132/133

U52

U600

U600

LU600

T2250mm

2605mm

-

Modeldesignation

EngineSales

designationInstallation

616.9151616.911

6139333

616standard

withSA35

613standard

Modeldesignation

Singleclutch

Salesdesignation

Installation

-

G250

KRstandard

Modeldesignation

Doubleclutch

Salesdesignation

Installation

-

DT240/225

Nspecial

versionSA

35814Model

designation

Maintransmission

Salesdesignation

Installation

717.802UG

2/27-6/14.53GA

standardModel

designation

sionSales

designationInstallation

-

VOG2/27-2/1.26

andVOG

2/27-3/4.67and

VOG2/27-4/42.88

.special

versionSA

35452Model

designationPower

takeoffVersionInstallation

-

shiftablespecial

versionSA

35448Model

designationFront

axleSales

designationInstallation

737.003737.005

737.004737.003

AU2/25-2,5

[AU

2/2ES-2.6AU

2/2S-2.5AU

2/2S-2.5standard

Modeldesignation

Rearaxle

Salesdesignation

Installation

747.007HU

2/2S-2.5747.009

MU2/2E5-2.6

747.0081MU_2/2S-2.5__J

-

standardModel

designation

SteeringSales

designationInstallation

-

ZF7340

orZr

8036standard

orspecial

versionSA

35521Model

designationSteering

pumpSales

designationInstallation

-

ZF7672

orZF

7673special

versionSA

35521Version

PlOshaft.

displacementRatio

gearsSpeed

nma1/mm

Installation

Input1/4"

Output1/8"

-

.i=

1-

3000special

versionSA

35303-

Modeldesignation

CabSales

designationInstallation

421.810

or421

.820-

standard‘Up

tochassis

endNo.

0098672Up

tochassis

endNo.

0104453Up

tochassis

endNo.

009854

lAlso

availablewith

2x4

shiftSA35451.

butwithout

auxiliarytransmission

UKD

304022103-06

1_ill

Overallview

General00

1.2/1

r

UKD30

40221

03-06

Vehicledimensions1

General00

Tiresize

10.5-18

Weelbasemm

2250

Trackwidth

mm

1403

Turningcircle

m9.1

to9.25

Turningcircle

mm

10350

Max.length

mm

4000

Max.width,

all-steeldriver’s

cabmm

1825

Largewidth,

Driver’scab

withfolding

topmm

1800

Vehicleheight

overdriver’s

cab,unloaded

mm

2200

Vehicleheight

overtarpaulin

frame,unloaded

mm

2290

Groundclearance

mm

387

Overhangangle

atfront

040

Overhangangle

atrear

70

Groundclearance

before-rearaxle

mm

385

Fordingdepth

mm

755

Heightof

thetrailer

couplingunloaded

mm

720

Noof

seatsin

thedriver’s

cab-

252

1all

specifiedvalues

withunits

olmeasurement

areapflrox.

values2

Dualcabin

3with

tires7,5-18

8PR

1393mm10,5-20

6PR1489mm

8PR

1393mm

Loadingarea1

shortplatform

mm

LengthInside

Longplatform

mm

1475

1753

Widthinside

mm

1500

Heightof

thesideboard

mm

360

Loadingheight

overground

unloadedmm

1140

shortplatform

m2EffectIve

arealong

platformm2

2.2

2.63

1all

specifiedvalues

withunits

ofmeasurement

areapprox.

values

UKO3040221

03-061.3/1

GeneralInformation

00

Max.speeds

6-speedgear

shift

Totalaxle

ratio

931

Max.speeds

km/hat

enginespeed

3000/mmand

3500/mmEnginespeed1/mm

Forwardspeeds

12

34

56

ReversespeedsI

2

Tires

.Main

speeds

tQ.s

Additionalcrawler

2speeds

30003500

3.944.60

7.138,32

12.7214.84

23.0226.86

34.7640.55

57.2667.00

4.925.74

6.921041

7.5-1810.5-18

30004.22

1.6413,64

24.6837.27

61.395.26

9.5710.5-20

35004.92

8.9115.91

28.7943.48

72.006.16

11.173000

4.277.74

13.8024.98

37.7462.16

5.469.68

10.5R20

12.5-187.5-20

35003000

‘4’ii’4.26

9.037.73

16.1013.79

29.1524.96

44.0337.69

72.5262.08

6.245.34

11.299.67

35005.07

9.1816.35

29.6144.72

73.666.34

11.473000

4.568.26

14.7226.64

40,2466.28

5.7010.32

12520

‘-

35005.32

9.6317.17

31.0846.95

77.336.65

104

30001.28

2.31-

--

--

7.5-1810.5-18

35001.49

2.70-

--

--

-

30001.37

2.4810.5

83500

1.602.89

-.-

--

30001.38

2.50-

--

--

-10.5R20

35001.61

2.91-

--

--

30001.38

--

--

-las-187.5-20

3500-

--

--

30001.47

2.66-

--

--

-12.5-20

3500-

.Intermediate

speeds

30003.13

5.5610.09

18.2527.57

45.413.90

7.077.5-1810.5-18

35003.65

6.5911.11

21.2932.17

52.984.55

8.153000

3,356.07

10.8219.57

29.5648.69

4.197.58

10520

*3500

3.917.08

12.6222.83

34.4956.81

4.888.84

30003.39

6.1410.95

19.8129.93

49.304.24

7.6810.5R20

35003.96

7.1612.77

23.1134.92

57.5149.24

495896

30003.39

6.1310.94

19.7929.89

4.237.67

12.5-187.5-20

3500-

--

--

--

-

30003.62

6.5511.67

21.1331.92

52.574.52

8.19125

20.

3500-

--

--

--

-

t2

Crawlerspeeds

1‘C

30000.844

1.5282.724

4.932-

-1.055

1.9107.5

1810.5-18

35000.985

1.7833.178

5.754-

-1.230

2.2283000

0.9061.639

2.9215.289

--

1.1322.045

105-20‘

35001.057

1.9123.408

6.171-

-1.321

2.3893000

0.9171.659

2.9575.353

--

1.1462.074

10.5R203500

1.0690.915

1.9363.450

6.246-

-1.337

2.423000

1.6572.953

5.348-

-1.145

2.07212.5-187.520

3500-

--

--

--

-

30000.977

1.7693.153

5.708-

-1.22

2.21212.5

203500

.

Worm

gearspeeds

30000.092

0.1670.297

0.537-

-0.115

0.2087.5-1810.5-18

35000.107

0.1950.347

0.627-

-0.134

0.2423000

0.0990.178

0.3180.576

--

0.1230.223

10520

35000.116

0.2080.371

0.672-

-0.144

0.2603000

0.0990.181

0.3220.583

--

0.1250.226

10.5R203500

0.1160.211

0.3760.680

--

0.1453

30000.099

0.1800.322

0.582-

-0.124

0.22612.5-187.5-20

350030003500

-

0.106-

-

0.193-

.

0.343-

-

0.621-

--

--

-

0.133-

-

0,241-

--

12520

.

1Standard

2cannot

betilted

withsleeve

shift

UKD30402

2103-061.4/1

00General

Information

Max.speeds

6-speedgear

shift

Totalaxle

ratio

8.81

Max.speeds

km/hat

enginespeed

30001mmand

3500/mm

Enginespeed1/mm

Forwardspeeds

12

34

56

Reversespeeds1

2

Tires

Mainspeeds

30003.71

6.7211.99

21.7032.77

53.984.64

8.417.5-1810.5-18

35004.33

7.8414.00

24.3538.25

63.005.42

9.823000

3.987.21

12.8623.27

35.1457.88

4.989.02

10.5-203500

4.658.41

15.0227.15

41.0067.60

5.8110.52

30004.03

7.3013.01

23.5635.58

5&615.04

9.1310.5R20

35004.70

8.7015.18

27.4841.51

68.375.88

10.653000

4.027.29

13.0023.53

35.5358.53

5.039.12

12.5-187.5-20

3500-

--

--

--

-

30004.39

7.9414.15

25.6238.70

63155.48

9.9112.5-20

7.5-1835003000

-

1.202.18

--

--

--

--

---

Additionalcrawler

speeds2

35001.41

2.54-

--

-10.5-18

30001.29

2.34-

--

-.

10.5-203500

1.512.73

--

--

---

30001.30

2.3610.5R20

12.5-187.5-20

35003000

1.521.30

2.752.37

--

--

--

--

--

--

3500-

--

--

--

-

30001.39

2.51-

--

--

-12.5-20

3500-

--

--

-

Intermediatespeeds

30002.95

5.339.51

17,2125,99

42.813,68

6.677.5-1810.5-18

35003.45

6.2211.10

20.0130.31

49.904.31

7.783000

3.165.72

10.2018.45

27.8745.90

3.951.15

10.5-203500

3.706.68

11.9121.53

326153.60

4.628.34

30003.20

5.796.76

10.3212.04

18.6828.2232.92

46.4854.22

3.997.24‘-

8.4410.5R20

35003.73

21.804.66

30003.20

5.7810.31

18.6628.18

46.423.99

7.2312.5-187.5-20

3500-

--

--

--

-

30003.41

6.1711.00

19.9230.09-49.56

4.267.72

12.5-20

7.5-1835003000

-

0.796-

1.441-

2568-

4,650-

-0.995

1.801

iQ‘00Crawler

speedsX0<

35000.928

1.6822.990

5.420-

-1.161

2.10510.5-18

30000.854

1.5452.754

4.986-

-1.067

1.93110.5-20

35000.998

1.804

!–

3.2305.820

--

1.2452.254

30000.864

&!!!

5.0481.080

10.5A203500

1.0081.825

3.2535.889

--

1.2602.281

30000.863

1.5622.784

5.042-

-1.079

1.95312.5-187.5-20

3500-

--

--

--

Worm

gearspeeds

-

30000.921

1.6682.973

5.383-

-1.152

2.08512.5-20

7.5-1810.5-18

350030003500

-

0.0870.102

-

0.1570.183

-

280

0.327

-

0.5060,590

---

---

-

0.1080.126

-

3.1960.229

30003500

0.0930.109

0.1680196

0.3000.350

0.5430.634

--

--

0.1160.135

0.2100.265

10.5-20

30000.094

0.1700.303-

0.549-

-0.118

0.213l0.5R20

12.5-187.5-20

350030003500

0.110DM94-

0.2000.170-

0.3540.304-

0324-

0.6410.549-

---

---

0.1370.117-

0.2480.213-

0.227-

30003500

0100-

0.182-

0.586-

--

--

0.125-

12.5-20

‘SA

35555

2cannot

betitled

wilhsleeve

shift

Ct00,CCt1.4/2

GeneralInformation

00

Max.speed

2x4-speed

gearshiftS

A35451

Totalaxleratio

8.3

Max.speeds

km/hat

enginespeed

3000/mmand

3500/mm

Enginespeed1/mm

Forwardspeeds

12

34

56

78

Reversespeeds

12

34

Tires

Mainspeeds

30003.94

7.1310.78

17.7512.72

23.0234.76

57.264.92

8.9213.47

22.187.5-18

10.5-183500

4.608.32

12.5820.71

14.8426.86

40.5566.80

5.7410.41

15.7225.88

30004.22

7.64-8.91

11.5519.03

13.64-15.91

24.68

28.79

37.2761.39

71.62

5.28

6.16

9.57

11.17

14.45

16.66

23.78

27.7410.5-20

3500-4.92

13.4822.20

43.48

30004.26-4.99

7.73

9.03

11.6919.24

13.7924.96

29.15

37.6962.08-72.52

5.349.67-11.29

14.61-17.06

24.05-28.10

12.5-1810.5R207.5-20

350013.65

22.4716.10

44.036.24

30004.56

8.26-

12.4720.54

14.7226.64-

40.2466.28

5.7010.32-

15.59-

25.6812.5-20

35005.32

9.6314.55

23.9617.17

31.0846.95

77.336.65

12.0418.19

29.96

Totalaxleratio

8.8

Max.speeds

km/hat

enginespeed

3000/mmand

3500/mm

Enginespeed1/mm

Forwardspeeds

12

34

56

78

Reversespeeds

12

34

Tires

Mainspeeds

30003.71

6.7210.16

16.7311.99

21.7032.77

53.984.64

8.4112.70

20.917.5-18

10.5-183500

4.337.84

11.8618.84

14.0024.35

38.2563.00

5.429.82

14.8324.41

30003.98

7.21-

10.89-12.71

17.9412.86

23.2735.14-41.00

57.884.98

9.0213.62

22.4210.5-20

35004.65

7.4121.85

15.0227.15

67.605.81

10.5215.90

26.20

30004.07

7.29-8.51

11.02-12.86

18.1413.00

23.5335.53

58.535.03

9.1213.77

22.6712.5-1810.5R2075-20

35004.70

25.7015.17

27.4841.51

68.375.88

10.6516.08

26.49

30004.30

7.7811.76-13.72

23.5113.88

25.1237.94

62.495.38

9.7314.70

24.2112.5-20

35005.02

9.0827.42

16.1929.31

44.2672.90

6.2711.35

17.1528.24

Totalaxleratio

7.621

Max.speeds

km/hat

enginespeed

3500/mm

Forwardspeeds

12

34

56

78

Reversespeeds

12

34

Tires

5.049.13

13.8022.43

16.2829.46

44.5173.30

6.3111.41

17.2528.40

10.5-18

5.139.63

14.5523.66

17.1631.07

46.9477.30

6.6512.04

181929.95

10.5-20

5.439.84

14.8624.16

17.5331.73

47.9478.96

6.7912.30

18.5830.59

10.5R20

5.529.99

15,0924.54

17.8132.23

48.6980.20

6.9012.50

18.8731.07

12.5-18

5.8010.49

15.8425.77

186933.84

51.1284.19

7.2413.11

19.8132.62

12.5-20

1Appllcabletovehiclemodel42l.126/129

UKD30402

2103V61.4/3

Weightsand

axleloads

Weights

General00

ChassisTires

perm.axle

WeightsModel

Salesdesignation

VersionSpeed

restrictionto

km/h

SizeType

PRloads

FAHA

kgkg

Deadveight1

kg

perm.pay-loadkg

perm.grossvehicle

kg

3

30km/h10.5-20

3-10.5-18

610-

68

25002500

6810-

81014

26002600

IFollowing

equipmentare

containedin

deadweight:

cascadebox,

specialPrO,

hydraulicsystem,

powerlift,compressed

airsystem,spare

wheel,long

auxiliaryloading

area,front

andrear

ptoshaft

and80kg

for otherequipment.2

2100kg

withoverall

axleratio8.3

2200kg

withoverall

axleratio

8.83

heavyattachments

andsnow

clearingattachments

arenot

permissible.4

OperatIngInstructIons:

Thevehicle

mustbe

equippedwith

hydraulicsteering

andwith

speedplates

40km/h

Whendriving

thetour-wheel

drivemust

beswitched

on.It isnot

permissibleto

widenthe

track.

1.5/1

8210022002

7.5-18

10.5-18

10.5-20

210020002

421.124U52

.125

.140U600

.141

.124U

52.125

.140U600

.141

Standard

MPT

none10.5-

18

10.5-20

12.5-18810

2500

2600

2500

2600

3

20km/h3

withheavy

attachmentsmax.

40km/h

.124U

52.125

.140U600

.141

.124U

52.125

.140U600

.141

10.5-18

MPT

61068106881014

3

20km/h3

30003000

12504100

13504200

12504100

13504200

2850

20004850

26505500

28505700

10.5-20

.124.125

U52

3

30km/h

10.5-18

61068

withsnow

clearingattachments

Tiax.40

km/I.140

U600.141

34003400

3-10.5-20

MPT

68103550

355081014

UKO3040221

03-06

00General

Trailerloads

Vehicle

ModelSales

VersionSpeed

designationrestriction

kg

Permissibletrailerload

kgTrailer

Trailerunbraked

brakednot

continuousbrakesystem

kg

Trailerbraked

continuousbrakesystem

kg

421.124.125

U52

Standard-

12508000

13200

421.140.141

U600macc.

withEEC

14258000

13100

421.124.125

U52

Withheavy

attachmentsfour-wheel

drive

201250

800012540

421.140.141

U600

401425

800012450

421.124.125

U52

Withheavy

snowclearing

attachmentsfour-wheel

drive

30None

NoneNone

40421.140

.141U600

1.5/2

Fluids,FillingCapacIties

GeneralInformation

00

GroupFluid

pageno.

ofMB

specificationsfor

serviceproducts

SAEGrade

SeasonCapacity

I

Enginewith

oilfilter

Engineoil

226-227.18

6

max.7.0

mm4.5

0.81.0

ofwhich

inoilfilter

oilbath

airfilter

Transmission

Maintransmission

Transmissionoil

235.1

80’80w6

SOw/85w’85w190’90

allyear

6.0

7.0

7.0

-with

auxiliarYtrans-

missionandlwithout

PTO-

withcrawler

gearbelow

PlOshafts

PTOshaft

bearing1

Transmissionoil

235.180

allyear0.11.4

Displacementgears

Axles

Differentialhousing

Hypoidtransmission

oil235

90

allyear

2.50.250.001

0.3

Wheelhub

driveDifferential

lockInitial

operationoil225.3

lOW

Expansiontank

fordifferential

lockInitialo?eration

oil225.3orATF

236-2lOW-

SteeringPower

steeringEngine

oil226,227

orATF

5326.2

10W2

all year2.0

0.6mechanical

Transmissionoil

80

Hydraulicsystem

Oilreservoir,

totalEngine

oil226,227.1

orhydraulic

cii341

lOW3

-

allyear15.013.0

7.0

whenchanging

oilperm.

removalBrakesystem

TotalcapacityBrakefluid4331.1

-allyear

0.8Compressed

airsystem

withoutantifreeze

unitAntifreeze

325

allyearas

required0.2

withantifreeze

unitEthyl

alcohol-

Clutchactuation

Expansiontank

Brakefluid

331.1or

331.2

all year0.2

Lubenipple

Axle,universal

shafts,power

lift,chassisLubr.

grease266

ormultipurpose

grease267

allyearas

required

DBropeFront

winch

Rear

TypeA

Transmissionoil235.180

allyear0.751.25

TypeC

Type4000

HATF

5or

engineoil

226/227/236.210W

allyear2.0

1Permanent

filling2

Incold

zonesuse

SAE5W-20130

3In

hotzones

useME

30,Incold

zonesSAE

SW-20/304change

onceayear

safetyrule

5ATF

oilsmust

notbe

mixedwith

otheroils

6Optional

?In

hotzones

8viscosity

ranges

Duringcontinuous

outsidetemperatures

above+30C

86SFSAE

40may

beused.

UKO304022103-06

1.6/1

00General

Information

GroupFluid

pageno.

ofMB

specifications forservice

products

SeasonCapacity

I

Battery-Terminals

Anti-acidgrease

Ft4OV1350

allyearas

required-Topping

upDistilledwater

Fueltank

StandardDiesel

fuelDIN

51601all

year90

Coolingsystem

withheater

Coolant6325

allyear

17.0

15.0

675

*

0.2

withoutheater

ofwhich

antifreezeprotection

to-25°CAntifreeze

andanti-corrosion

protectionTreating

agent311

Windshieldwasher

Windshieldwater

bottleMB

windshieldwasher

cleanerallyear

2.4

comprisingwater,

antifreezeand

treatingagent

7jantifreezeprot.antifreeze

tot

approx.%10

2020

3425

4030

4440

51

1.6/2

GeneralInformation

00

ChassisType

411

TechnicalData

ModelType

411shorter

longerChassis

dimensions:Wheelbase

Wheelbase1720mm

2120mmTrack,

front1290mm

1290mmTrack,

rear1295mm

1295mmTrack

withreversed

wheels,front

1538mm1538mm

Trackwith

reversedwheels,

rear1543mm

1543mmMm.

trackcircle

diameterouter

track7,6

m9,1

mMax.

length3460

mm

3860mm38600

*

Max.width

1630mm1630

mm17900*

Max.height

2035mm

2035mm21400*

Clearancebelow

differential380mm

380mm

Clearancebelow

axle460

mm

460mm

Platformlength

i.I.

1475mm1475mm

1875*000

Platformwidth

i.w.

1500mm1500mm

Platformheight

i.h.

360mm

360mm

Effectiveloading

area1475

x1500

mm

2,2m2

2,2rn

2,8Loading

heightabove

ground,unloaded

1065mm1065mm

Heightof

trailercoupling,

unloaded780mm

780mm

Seatsin

cab1/1

1/1lilting

angle380

38°Angle

ofapproach,

front/rear38°/47°

38°/62°

Weights:

GVW

3200kg3500kg***

Deadweight1795

kg1895

kg1940"

Payload1000kg

l200kg***Perm.

frontaxle

load1900kg

1900kg

Perm.rear

axleload

2000kg

2000kg

Recommendedtotal

trailerweight

16t

16

=In

agriculturalfield

operationsweight

oftractor

iareduced

byapprox.

135kg

whenwindshield,

roofare

removedApplIcable

toIJNIMOG

Type411

withsteel

cab.=

Applicableto

Germanversion

withnormal

loadingplatform.

GVW

ofexport

modelwith

lamerloading

platformis3550

kg.payload

1600kg

=Applicable

toexport

versionwith

largerloading

platform.

UKD304022103-06

2.1/1

00General

Information

I.Liftingcapacity

ofhydraulic

powerliftarms

aRear

powerlift

Thecapacity

ofthe

powerliftsystem

rangesfrom

470-525mkp

dependingon

connection.Liftingpower

atimplement

connectionsof

3-pointlinkage

at550mm

couplingheight

andaverage

lifting spindlelength

of100

mm

clearthread:

Centreof

gravitybehind

swivelbearings

m

Liftingcapacity

kp

BA-

frontBA

-rear

Liftingheight

atcentre

ofgravity

mm’

BA-

frontBA

-rear

00,40,81,01,21,4

1190900750690630580

13501010850790730680

410555710775825850

390520610640675690

Not*;BA

bottomarm

*The

max.stroke

atcentre

ofgravity

takinginto

accountcoil

springsand

flatteningof

tire;does

nottake

intoaccount

losseswhich

occurin

fIoatinposition.

bFront

powerlift

Max.lifting

powerwith

largestperm.

pistondiameter

Pressure6000

kpof

hydrauliccylinder

72mm

Traction5000

kp

II.Liftingcapacity

ofpneumatic

powerlIftarms

aRear

powerliftarms

Max.lifting

capacityat

implementconnecting

pointswith

distancebetween

centreof

gravitiesof

implementfitted

asfollows:

Distancebetween

centreofgravity

cm

Liftingcapacitykp

0255080120150

Type4Ol*64555046035020090

Type4Il**830730630520360240

bFront

powerliftarms

8.5bar

operatingpressure

Max.liftingpower

of35cmlong

armliftingcylinderconnection

upto

pivotingaxiswith

distancebetween

centreof

gravitiesof

implementfitted

asfollows:

Distancebetween

centreof

gravitiescm

Liftingcapacity

kp

406080100120150

640570510440370270

*Applicabl,

toold

powerliftsystem

with7.6

baroperating

presser,hydraulic

cylinderwith

1700mmdiameter.

=Applicable

tonew

powerliltsyatem

with8.5

baroperating

preaeurehydraulic

cylinderwith

190mmdiameter.

2.1/2

GeneralInformation

00

WheelsRim

sizedrop

baserim

5.50Fx18

W9

x18

Press-indepth

58

Press-indepth

25Tires,

frontand

rear7.50-18

1O$.-i8Tire

pressures:

Onhighways

Front2.75

kp/cm2,rear

3.0kp/cm2

Frontand

rear2.0

kp/cm2Off

highwaysup

to20

km/hFront

andrear

1.5kp/cm2

Frontand

roar1.2

kp/cm2In

fieldsup

to8km/h

Frontand

rear1.25

km/cm2Front

andrear

0.8-1.2kp/cm2

P10rpm

Outputapprox.

30HP

PTOrpm,

normalFront

andrear

540rpm

Beltpulley

drive,side

1170rpm

Speedranges

Max.speed

in6th

gearapprox.

53km/h

in5th

gearapprox.

35km/h

in4th

gearapprox.

21km/h

in3rd

gearapprox.

12km/h

in2nd

gearapprox.

6.5km/h

in1st

gearapprox.

3.5km/h

in1st

reversegear

approx.2.6

km/hin

2ndreverse

gearapprox.

4.8km/h

Crawlergear

max.speed:

in1st

gearapprox.

1.15km/h

in2nd

gearapprox.

2.08km/h

Crawlergear

mm.speed:

In1st

gearapprox.

0.300km/h

in2nd

gearapprox.

0.600km/h

Crawlergear

withintermediate

gearmax.

speed:in

1stgear

approx.2.8

km/hin

2ndgear

approx.5.0

km/hFuel

consumptionon

leveJroad

withouttrailer

approx.9-10

1/100km

at40

km/hin

6thgear

inthe

field2-6

I/hdepending

onkind

ofJob

oilapprox.

120g/h

consumptionof

engine,normal

upto

Capacitiesof

coolantsand

lubricantsWater:

Capacityof

coolingsystem

engineand

radiator13

ltr.Lubricant:

Engineoil

panmax.

6ltr.

Engineoil:

mm.3.5

ltr.Air

compressor0.14

Itr.Air

filter0.25

ltr.Hydraulic

system:approx.

8.5ltr.

Transmissionoil:

Transmissionapprox.

6Itr.

Transmissionwith

crawlergear

approx.7

ltr.Front

andrear

axlehousing

onType

411approx.

3ltr.each

fromType

411bapprox.

2Itr.each

Wheelhub

drive4

0.3Itr.

eachSteering

housing0.75

ltr.Fuel:

Fueltank

60Itr.

prey.40

Itr.Brake

fluid:Brake

systemapprox.

0.6ltr.

Transmissionfluid

ATF:Differential

lockapprox.

0.3Itr.

UKD304022103-06

2.1/3

00General

Information

Positionof

frontwheels

Toe-inunloaded

vehicle

CamberCasterInclination

Frontand

rearaxle

Spiralbevel

gearAxle

drivereduction

aType

411,411a,411b

bType

411b/411cfrom

frontaxle

no6457

fromrear

axleno.

6194

Klingelnberggearing

25:7

=3.57:

1

35:9

=3.89:

Reductionon

wheelhub

driveDual

reduction

Backlashof

crownand

pinionAxial

playof

crowngear

mci.differential

housingin

bearingseats

Backlashof

differentialbevel

gearsclearance

axialof

doublejoint

shiftin

wheelhub

drive

Shockabsorbers

ManufacturerTypeDimension

Swings

32:15=2.13:1fora

itotal=1:

7.62forb

itotal=1:

8.290.15-0.20

+0.002

to0,05

0.15-0.20

0+0.02,

nopreload

StabilusTelescopeT40x

13040

mm

piston0,

maintenance-free

Basicdesign

reinforceddesign

FrontsprIngs

Untensionedlength

Springdeflection

per100

kgload

Rearsprings

Untenslonedlength

ofmain

sprIngSpring

deflectionper

100kg

loadUntensloned

lengthof

helperspring

Springdeflection

per100

kgload

Brakes

2coil

springs320

–3mm

15.95mm

9.10mm

2coil

springswith

2helper

springs

360–

3mm

17.70mm12.45

mm

250–

3mm

11.60mm

Footbrake

Effectivebraking

areaper

wheelPlay

betweenthrust

rodand

pistonot

masterbrake

cylinderFree

travelof

brakepedal

measuredat

runningplate

Hydraulicbrake

systemacting

onall

fourwheels

494cm2

10

HandbrakeActing

mechanicallyon

rearwheels

Adjustingand

InstallationInstructions

Type411

Dimensionsinmm

1045’

approx.4°

100

2.1/4

GeneralInformation

00

Steering*Type

411Spindle

steering"Fulmina"

Type30

Playat

steeringwheel

20-30Steering

wheelPetri

4500

Reduction1:

24.3=5.06

steeringwheel

turns=

75°turn

ofsteering

armSpindle

Doublethread

lefthand16

mm,*ZF

powersteering

optionalinclination...

Stg.<

9°35’

Clutch

I.SingleClutch

ManufacturerFichtel

&Sachs

Singleplate

dryclutch

TypeK225

Thrustpressure

90kp

Clutchpedal

clearancemeasured

atrunning

plate20-25

Contactarea

ofclutch

plate221

cm2Thickness

ofclutch

platemd.

loaded9.3

–0.3

mm

clutchlining

unloaded9.8

–0.3mm

II.DoubleClutch

ManufacturerFichtel

&Sachs

Doubleclutch

TypeDo

225/200K

Thrustpressure1.

Firststage

driveclutch

approx.120

kp2.Second

stagepto

clutchapprox.

250kp

Clutchplay

1,5mm

TransmissIon

Axialplay

ofdrive

for4-wheel

drive0.20

-0.30

Axialplay

ofcountershaft

betweencover

andspacer

ring0.20

+0.1

Radialplay

betweenbushing

andfirst/third

gearcounter

shaft-

slidingbearing

0.13-0.19All

wheelsets

musthave

aperceptible

playafter

installationapprox.

0.1-0.2

mm

Remainingaxial

playsof

individualshafts

forthe

recessesof

rollerbearings

andstages

ofthe

shaftare

given

KD

304022103-062.1/5

00General

Information

Pneumatichailer

brakesystem

ManufacturerSingle

pistonair

compressorCapacityMax.

rpmof

aircompressor

Operatingpressure

Deliveryat

7.3kp/c2

counterpressureand

max.rpm

of2750Pressure

regulatorwith

tireinflating

bottlePressure

regulatorset

operatingpressure

Pressureregulator

withtire

inflatingbottle,

adjustable:for

trailerbrake

forpower

liftarms

Doubleline

brakesystem

Hydraulicallyoperated

brakevalve

Pressureregulator

Brakepressure

Singlepiston

aircompressor

withgear

oilpump

Type/Designation*

Aircompressor

Aircompressor

rpmCapacityOperating

pressureDelivery

at7.3

kp/cm2counterpressure

andmax.

rpmof

2750rpm

Hydraulicsystem

**Gear

oilpump

withair

compressorGear

oilpump

Oilpump

rpmOperating

pressureDelivery

atmax.

enginerpm

of2750

withoutcounterpressure

Deliveryat

operatingpressure

Hydraulicdouble

valvewith

pressurereliev

valve

Westinghouse,Hannover

Type411004

1200

98cm32450

rpm7.5

kp/cm2

approx.120

1/mm

Type4753040010

5.2kp/cm2

Type475

305000

05.2

kp/cm28.5

kp/cm2

Type470

006001

0Type

475304

0010

7.2kp/cm2

Westinghouse/415701

1000

Type411

00510002450

rpm96

cm37.35

kp/cm2

approx.120

1/mm

Westinghouse415701

1000Type

416101

00002450

rpm150

kp/cm2

18.51/mm

18ltrimin

Type4667990000

f.

2.1/6

TighteningTorques

inkpm

Engine

GeneralInformation

00

CD''

CDfi

fi,,

a=

Tightenbolts

withthread

MSwith

handwrench.

Cylinderhead

boltsare

slackenedin

thereverse

order,starting

fromthe

back.

1Connection

rodand

mainbearing

boilsare

tightenedwIthout

ioclcingplates

tothe

recommendedtorque.

Beforetightening,

greasethreads

otboils

andnuts.

2TIghten

expansionbolts

lotfiywheei

mounting:tirst

step3+1

mkp,angle

oftorqueocfi

+i.

3When

tighteningrocker

annmounting

bolts,rocker

annashould

notbe

subjectedto

loadby

camshaft.

TypeCM

615CM

621CM

636Crankshaft

bearingbolts

91

98

Pistonrod

bolts5.5

4.1-0.6

3.75Flywheel

mountingAngle

torque215.5

+0.5

Cylinderhead

boils9

98

Thrustbolt

ofprechamber

15+3

15+3

15Nozzle

innozzle

holder7+

17+

1Nozzle

holderin

cylinderhead

7+

17+

1Glow

plugs5

5Pressure

valvecarrier

atinjection

pump4.5

+0.5

4.5+0.5

Capnuts

ofinjection

lines2.5

2.5Rocker

armbearing

bracketbolts

3*7533753

Nutsfor

ringpiece

onnozzle

holder7-

17-

15

Polit-stopnut

onmt.

gearshaft

formounting

timingdevice

77

Collarbolt

oncrankshaft,

front21

+1

2118

Mountingbolts

foroil

filterlower

part4-0.5

4-0.5

-

Oilpressure

valvein

cylindercrank

case4

4+

1-

Cylinderhead

cover1.0

2.5-

Oilfilter

pot4-0.5

4-as-

Frontengine

mounting6

6-

TypeSketch

for tighteningsequence

ofcylinder

headbolts

Torqueingin

stagesTightening

torqueinmkp

Firststep

Secondstep

Thirdstep

Check

0M621

0M615

cfifififi'fifi'fi’I

Lfifififi'fifi'eiz4955

34

69

9

69

9

OM636

46

$8

UKO30402

2103-062.1/7

00General

Information

Transmission421

Bolt,small

bearingmain

shaftrear

1Front

andrear

axle421,

411b,41Ic

Stabilizer18-20

Axledrive

adjustment12

kpcm

Boltson

wheelhub

drivehousing

andthrust

tube9-10

Boltson

axledrive

housing13,5

Clampingbolt

inwheel

hubdrive

22

Wheelhub

bolts29

Shockabsorber

fasteningbolts

12-14

Axlestruts

boltsM16-10

K22

–2

Steeringarm

atsteering

knuckle22

Frontand

rearaxle

411,411a

Fasteningnut

forstrut

onmounting

bracket7.5-8

Fasteningbolts

ofcrown

gearof

differentialhousing

7-8

Slottednut

atbevel

gearshaft

14-16

Hexagonbolts

forsteering

knucklesand

connectionhousing

ataxle

bridge,resp.

24

Mountingbolts

ofstabilizer

17

Wheellocking

bolt75-100

Steering421

*411

Steeringarm

25-30

Steeringmounting

onframe,

boltM24

x1.5

40

2.1/8

Electricalequipment15

SurveyVersion

Engine616

15.9

Model421,

41115

UKD

304022103-5

Electricalequipment

15.9

616

Contents

ChapterPage

1General

Technicaldata

alternator1.1/1

Sectionalview

1.1/1Technical

datastarter

motor1,1/2

Sectionalview

1.1/2Technical

dataglow

plugs1.1/3

Specialtools

1.2/1Tightening

torque1.2/1

Explodedview

1.3/1

UKD30402

2103-06

General15.9

Technicaldata

Alternator

Electricalsysteni12

Voltl2VoIt

24VoltSeries

SA35496

SA356131

ManufacturerBosch

DesignThree-phase

OutputW

490770

756Rated

voltageV

1428

CurrentA

35I

27Number

ofrevolutions,

max.11mm

900011000

Startof

charging1/mm

10001180

Gearratio

engine/alternator1:

ISOInscription

K1-14V35A20K1-14V55A20

IK1-26V27A23

‘Engine-model616.933

Sectionalview

Alternator1

Heatsink

2Diode

3Slip

ring4

Statorwinding

5Stator

core

6Drive

bearing7

Fan8Claw

polerotor

9Carbon

brush10

Slipring

bearing

616

uz15-0013/i

UKD

30402

2103-06

1.1/1

15.9General

Information

616

Starter

InstallationStandard

SA35

613

ManufacturerBosch

Construction

Type

Pre-engaged-drivestarting

motor

JF-*12V2.3kW

JF-.24V2.6kW

Marking-.12V0001362600

-.24V0001363106

Directionof

rotationto

theright

Ratedvoltage

V12

24

OutputkW

2.32.6

Piniongearing

No.of

teethz

Modulem

Pressureangle

a°

Profiledisplacement

factorx

910

2.110

12

+0.753

9Solenoid

relay10

Relaycontact

11Terminalstud

12Bridging

contactmember

13Carbon

brush14

Commutator15

Poleshoe

16Exciterwinding

17Starterarmature

18Armaturewinding

19Guide

ring20

Stop21

Roller.typeoverrunningclutCh22

Armatureshaftwith

spiralspline

Starter1

Pinion2

Driver3

Brakedisk

4Meshing

spring5

Engaginglever

6Return

spring7

Holdingwinding

8Pull-in

winding/

11/2

General15.9

616

Glowplugs

InstallationSeries

SA35613

ManufacturerBosch

BeruBosch

Beru

TypeKE4484B/A

182MJA250201020

165MJ

Typeof

connection1pole

Operatingvoltage

V9.5

18

Operatingcurrent

A9.1

105.2

Number4

Lengthmm

79.578

78.5

Maleconnector

MlBx

1.5

Standardinstallation

Engine-modelto

engine-end-no.

616.911003345

616.932000380

616.933000204

InstallationSeries

SA35613Manufacturer

BeruBeru

Type0100221

1070100231101

Typeof

connection1pole

Operatingvoltage

V11.5

18

Operatingcurrent

A14

5

Number4

Lengthmm

68–

1

Maleconnector

M12

x1.25

Standardinstallation

Engine-modelfrom

engine-end-no.

616.911003346

616.932000381

616.933000205

UKD30402

2103-06

1.1/3

General15.9

616

SpecialtoolDesignation

Specialtool

Tool-seet

123

Boxwrench

Socketwrench

forglow

plugsReamer

forglow

plugduct

000589300300001

589230900617589005300

AAD

Tighteningtorques

DesignationNm

Alternatorat

carrierM

8/8.838

Clampingbolt

atcrankcase

M10/10.9

50

Beltpulley

atalternator

NI14

35to

45

Glowplug

incylinder

headM

1850

M12

35

Startermotor

atclutch

housingM

12/8.855

to65

UKD3040221

03-061.2/1

General15.9

Explodedview

58IaElectrical

equipmenton

engine

28Glow

plug48

Exciter-diode31

BusbarO

Setof

brushes35

Nut53

Spring37

Cap54

Repairkit

rotor38

Plug56

Beltpulley

39Bracket

57Fan

40Bracket

58Woodruff

key40D

Nut60

Springwasher

41Alternator

62Nut

41D

Ballbearing

65Earth

cable41H

Ballbearing

70Angle

42Rectifier

73Bolt

43Plus-diode

75Springer

washer46

Minus-diode

616

4111

t4643

0Z15-0020

UKID30

40221

03-061.3/1

15.9Generai

Explodedview

Startermotor

UZI5-0019 c

4Starter

motor5

Exciterwinding

7Bolt

9Set

ofbrushes

OSpring

12Pinion

13Bushing

14Shift

lever

14015161719222426

BoltBushingBushingBushingSOIeflQid.operafed

switchintermediate

pieceSpring

washerBolt

CC16

1.3/2

II.Type

4fl

StarterBoschorder

no.Type

IRotating

Max.Torque

directionShort

circuitcurrent

input

0001354031

IDR

12V

1.8PS

clockwise

4.1kpm

845Amp.

Regulator

Glowplugs

Boschorder

no.Type

-rExecution

ofglow

wireRated

voltage________________

0250002002

0250001001

BoschKE/GA

2/2Bosch

KE/GA1/8

coilspring

likeloop

like1.4V0.9V

--

Beru202

GEBeru

214GK

lAY

coilspring

like0.9V

1ooplike

Remark:The

shaftof

theBeru

glowplug,

ofwhich

theglow

wireiscomming

out,isnot

alive

one,therefore

notground

sensetive.

15/54-0/5

Tableof

electricalcircuit

onengine

OM

636all

fuses8Amp.

asper

DIN72581

Fuseno.

Consumer

1Back-up

light2

Taillight,

left3

Taillight,

right,instrument

panellight

4Blinker

5Horn

andwindshield

wiper6

Stoplight

7Main

beam,left

8Main

beam,right

9Dimming

light,left

10Dimming

light,right

11Parking-and

positionlight,

right12

Parking-andposition

ligth,left

Picture15/54-0/4

Arrangementof

fuses

Picture15/54-U/S

1=

Generalorreguictor

2=

Blinkersending

unit3=

Fuseboxes

15/54-0/6

Explanationfor

wiringdiagram

Picture15/54-0/6

1=

Headlight,

left2=

Headlight,

right=

Blinl-ondposition

light,left

4=

Blink-andposilion

light,right

=Engine

6=

Generator7=

510rler

BFuse

boxes9=

Windshieldwiper

10=

Plugfemale

11=

Blinkersending

unit12

=Glow

plugresistance

13=Glow

plugcontrol

14=

Highbeam

indicationlight

15=

Chargingcontrol

light16

=Panel

instrumenttight

17=

Blinkercontrol

light,br

1sttrailer

18=

Blinkercontrol

light,for

2ndIroiler

19°Oil

pressureswitch

19b=

Oilpressure

controllight

20Glow

plugstarter

switch21

=Main

switchbats

22=

Switchfor

blinker23

=Horn

24=

Terminotroil

25=

Stoplight

switch26

=Button

forhorn

27=

Terminalroil

28=

Battery,12

V29

=Trouble

lamp30

=Trailer

femaleplug

wflhthe

connectionol

=Slop-blink

tight,right

Slop-blinklight,

leftGround

=Toil

hghtleft

=Tail

light,right

=Stop

light3rd

brokeR

54bottom

154

top3158

middle58

outside5452

31=

Blink-stop-andtail

light,left

32=

Blink-stop-andtoil

light,right

33=

Switchfor

controllight

troublelight

34=

Switchfor

3rdbroke

Picture15/54-0/6

Electricalwirina

diaaramtvoe

411

IllUI0

Remove,Install

andPartially

Repairthe

Starteron

Type421

15-1

Thestarter

isoperated

electricalvia

theglowplug

starterswitch

onthe

dashboard.

Ifthe

starterfails

tostart,

thereason

forfailure

maybe

inthe

electricalsystem

orin

thestarter

itself.Loose

terminalsand

badground

connectionsmay

bethe

reasonsfor

malfunctioning;the

usualpermissible

lossof

tensionshould

notexceed

morethen

4%in

thecable

goingta-and

fromthe

starter.

Thereaction

ofthe

switched-onhead

lightstell

thecondition

ofthe

batteryand

contactsof

thestarter.

aAre

thehead

lightsgoing

off,abad

connectionis

onthe

battery,on

thecable

connectorsof

thestarter,

oron

anyground

wire.

bAre

thelights

goingoff

slowly,the

batteryis

notcharged,

ordamaged,

orold.

cIf

thelights

ofthe

headlights

donot

changeat

all,the

starterneeds

achecking.

A.Remove

andinstall

starter

1.Remove

groundcable

frombattery.

4.Installation

isdone

invice-versa

sequences.2.

Disconnectcable

fromstarter.

Coatpinion

andpinion

shaftwith

grease.

3.Remove

starterfrom

crankcasehousing

inforward

direction.

B.Repair

starterpartially

Remark:

Ifthe

starterfails

towork,

itis

adviseableto

havea

servicestation

checkinto

itfor

torepair.

Therepair

instructionsof

thestarter

thereforedeal

onlywith

anexchange

ofthe

carbonbrushes

andsprings

aswell

aschanging

ofthe

starterpinion.

1.Remove

collectorprotection

ring.

2.Remove

brushes.Picture

15-1/1.Picture

15-1/13.

Placestarter

intovise,

decottercastled

nutof

pinionshaft,

removenut

withwasher.

4.Remove

pinionfrom

shaftby

turninganti

clockwise.

a.

15-1/1

11.Reassembly

isdone

vice-versa.5.

Removescrews

onstarter

housingcover

andtake

offcover.

6.Remove

armatureout

ofhousing.

7.Clean

brusheswith

fueland

aclean

Nevertouch

thesparkling

contactwith

afile

orsand

paper,clean

mountingswith

airpressure.

8.Clean

collector,if

groovescan

beseen,

turnoff

alittle

andpolish,

alsoclean

groovesbetween

thecollector

barsother

wiseshort

circuit.

9.Check

starterpinion,

ifnecessary,

renew.

10.Check

brushesand

brushpressure

springs,fnecessary,

renew.

C.Remove

andinstall

magneticswitch

cloth.ereasbrush

12.Check

starteron

testbench.

Picture15-1/2.

Installation:

1.Remove

groundcable

onground

po1of

battery.

2.Disconnect

cable30

and51

onthe

connection

ofthe

magneticswitch.

Removethe

cablefrom

thefield

windingsto

thema

gneticswitch.

3.Remove

thecontrol

cableon

theconnec

tion50.

4.Remove

thecylindrical

screwson

thecover

flangefor

thedrive

bearing,unhook

themagnetic

switchon

theengagement

leeverand

remove.

5.Check

theinstallation

measurement‘a"

onthe

magneticswitch

andif

necessaryadjust.

Seepage

15/54-0/1.

Afterthe

adjustment,the

universalfork

andthe

counternut

mustbe

securedwith

varnishFL

53V

8.

6.The

restof

theinstallation

isdone

vice-versa.

Picture15-1/2

Remove:

15-1/2

Remove,Install

andPartially

RepairStarter

onType

411

A.Remove

andinstall

starter

1.Remove

groundcable

onbattery.

2.Remove

startercable

30.

3.Loosen

electricwire

onconnection

50.

4.Loosen

connectingbolts

ofstarter

oncrank

casehousing

andremove

starter,use

toolno.

6365890001

00.

5.Installation

isdone

vice-versa.

B.Partially

repairstarter

Remark:

Forthe

repairof

thestarter,

thesame

rulesas

ofthe

generatordo

apply,that

meansbring

starterto

thenearest

BoschService

Station.The

descriptionof

starterrepair

onlygoes

forchanging

ofbrushes

andbrush

springsas

wellas

changingof

thestarter

pinion.1.

Removeprotection

coverplate

forcollector.2.

Tighteningscrewhex.

nutfor

el.wire

frommagnetic

switchto

thestarter

motorto

beloosend.

3.Lift

upbrush

pressurespring,

andremove

thebrushes.

4.The

2long

screwsto

betaken

out,remove

bearingcover1

mci.armature

beforetaking

out,mark.

5..If

thestarter

pinionis

tobe

changed,remove

themagnetic

switchby

looseningthe

twotop

countersunk

screwsand

thehorizontal

pintoo.

15-1.1

6.Decotter

castlednut

infront

ofthe

starterpinion,

removesame

andthe

lockring

too.

7.Remove

armatureout

ofits

frontmounting

bearing.

8.Pull

downshifting

fork.Starter

pinioncan

nowbe

removed.

9.Clean

andcheck

collector,if

necessaryuse

polishlinnen

toclean,

alsoclean

thegrooves

betweenthe

barsotherwise

shortcircuit.

10.Check

starterpinion

andif

necessary,renew.

11.Check

alsoand

ifnecessary,

renewthe

brushpressure

springsand

thebrushes.

12.Reassembly

isdone

vice-versa.

13.Check

starteron

teststand.

Picture15-1.1/1

1=

Connection30

2=

connection50

3=

connectionbolt

formagnetic

switch

15-1.1/1

Removeand

InstallGenerator

onType

421Three-phase

generator

I.In

general

Thegenerator

issuppling

thedirect

current,needed

forthe

electricalsystem

inthe

vehicle,converted

bythe

siliconrectifier

intodirect

currentdiode

inbridge

position.Converting

a.c.into

d.c.By

meansof

atwo-contact-one-

elementregulator,

theoperating

voltageis

regulated.The

generatoritself

regulatesthe

max.voltage,

therectifiers

aretaken

overthe

functioningof

thereturn

currentswitch.

Thegenerator

ispre-exited

bythe

batteryand

duringthe

operationthe

exitingisdone

byan

installed3

exitingdiode

inthe

coil.

Thethree-phase

generatorneeds

nomain

tenance.

Toavoid

greatdamages,

lookout

forthe

following:

1.As

longas

theengine

isrunning,

donot

removeignition

keyor

theterminals

onthe

battery,the

connectionon

thegenerator

itself,or

theplug

ofthe

regulator.Other

wisethe

diodeswill

bedamage

bythe

inductive

voltagepeak.

2.For

thesame

reasonit

isnot

pullaUNIMOG

aslong

asthe

batteryare

notconnected

avehicle.

3.The

three-phasegenerator

mustand

shouldnot

bepolarized.

Thepre-exiting

issufficient

aslong

asthe

controllight

ison.

4.By

nomeans

mix-upthe

terminalsor

theconnections

onthe

generator,regulator

orstarter.

5.Attention

whenquick

charging.When

re-chargingthe

batterywith

aquick

chargerbattery

installedin

thevehicle

removethe

terminals.If,

inexeptional

cases,the

quickcharger

isused

asa

starteraid

-as

bywhere

theterminals

arenot

removed-

theimplement

mustbe

shut-offbefore

disconnected.

Otherwisea

highvoltage

isinduced

bythe

suddenload

decreaseand

thediods

aredestroyed.

permissibleto

thecables

onwhen

loading

r--n

L-

--

-J

0+

1DF0-

1=

Regulator2

Plugconnections

3=

5crewconnections

4=

Loadingwarning

lightS=

Rectifier6

Battery7=

Threephasecoil

=Exting

coilrunner

15-2

Attention:Implements

withseperate

mainswitch

tobe

shut-offonly,

afterthe

loadvoltage

hasbeen

setbock

to0Amps.

Abad

connectionof

theterminal

canalso

leadto

destructionof

thediods

whena

starteraid

isused.

Theyare

alsoin

dangerwhen

aquick

chargeror

abattery

isconnected

thewrong

way,with

theone

inthe

vehicleacting

asstarter

aid.

6.The

regulatorconnections

northe

generatorshould

beshortened,

norshould

thehot

wirebe

connectedwith

theground

wire. 0

Picture15-2/1

15-2/1

7.Generator

troublein

generolare

mostlyshown

bythe

brightshining

indicationlamp

forignition.

Theexact

malfunctioningof

thegenerator

canonly

bedestined

ona

testbench.

However,the

generatorwith

regulatorcan

betested

whileboth

ofthem

areinstalled

asfollows:

aConnect

voltagemeter

onU+

andD-.

Withouta

switch-onconsumer,

theregu

latorvoltage

atengine

rpm.of

1500/mm.,should

befor

varioustypes

ofregulators,

between13.9

to14.8

V.

bShut-on

consumerhead

lightsand

wind

B.Remove

andinstall

generator

1.Disconnect

battery

2.Disconnect

wiresfrom

generator.Remark:Instead

ofa

cableshoe,

athree-fold-plug

connectionis

mounted.

3.Remove

setscrew

onbracket

ofgenerator,

removeV-belt.

Picture15-2/2.

4.Remove

screwon

supportof

generatorbracket,

takeoff

generator.

5.Installation

isdone

vice-versa,connect

cables.

6.Tension

V-belt

shieledAt

thisshouldlimits.

wipermotors

ofapprox.

200W.

consumer,the

regulatorvoltage

bewithin

therecommended

Ifthe

voltageis

notwithin

thislimits,

shut-offengine,

pullregulator

plugand

repeatchecking

withnew

regulator.In

casethe

regulatorvoltage

isnow

correctinstall

thenew

regulator.If

thevoltage

sstill

outof

thelimit

recommendedchange

generator.

Payattention

fora

surroundingtem

peraturof

theregulator,

app.20°

Cand

aload

capacityof

thebattery

of60

%.

Remark:Any

repairof

analternator

shouldbe

donein

anauthorized

BoschService

Station.

=Set

screwfor

v-bell2=

Screwof

generotorsupport

3Generolor

supportbrockel

Picture15-2/2

15-2/2

Remove,Install

andPartially

RepairGenerator

onType

41115-2.1

Therated

outputof

thegenerator

is130

W.The

generatorcan

beoverloaded

continouslyup

to

50%.

Thereserve

isto

chargethe

batteryeven

whenconsumers

areshut-on

headlights

atnight.

Continousconsumers

arethe

onesin

operationusually

allnight:

Headlight,

taillight,

licensplate

lightetc.

A.Remove

andinstall

generatorRemark:

Itmight

bea

goodidea

tohave

generator1.

Disconnectground

cableon

battery.run

asan

enginefor

alittle

while,therefore

2.Disconnect

wireson

generator.connect

no.61

with51.

3.Remove

setscrew

onbracket

ofgenerator

Dothis

beforeV-belt

ismounted.

andtake

offV.belt,

4.Remove

bothscrews

onthe

carrierof

Ifthe

generatorruns

inthe

samedirection

asgenerator

mountingbracket,

takeoff

theengine

does,this

isthe

rightdirection

andgenerator.

generatorhas

thecorrect

polaritytoo.

Provided5.

Installationis

donevice-versa,

thebattery

isconnected

inthe

rightway.

B.Partially

repairgenerator

Thegenerator

shouldonly

berepaired

inthe

inthe

bearingcover

andpull-off

theball

ownshop

ifno

BoschService

Stationisaround,

bearing.Use

puller000589203300.

Otherwisegive

generatorout

forrepair.

8.If

collectorshows

grooves,turn

down1.

Loosenand

removecollector

protectionslightly.

strap.The

isolationbetween

thecollector

bars2.

Liftbrush

springsand

brushestoo,

clampand

thebars

itselfmust

beset-back

bybrushes

withsprings

tohold,

dontbrake

0.6mm.

Ifthis

isnot

thecase,

useacollec

brushes.For

sawfor

cut-in.Clean

collectar.

3.Remove

bothlong

screws,also

thebearing

9.Clean

brusheswith

cleanrag.

Ifworn

out,cover

onthe

driveside,

includingthe

coil,renew.

Beforepulling

out,mark.

Thebrushes

shouldglide

inthe

brush4.

Loosenmounting

screwof

theplus

brushholder

easilyand

thesprings

shouldpress

holdercable

shoe.them

downsufficiently.

5.Remove

beoringcover

oncollector

side.10.

Reassemblingof

thegenerator

isdone

6.Remove

nuton

V-beltpully

andpull

offvice-versa.

V-beltpully

itself.11.

Checkgenerator

ona

testbench

orafter

7.Check

ballbearing.

Removethe

3screws

installationinto

vehicle.

15-21/1

ExchangeVoltage

Regulator15-3

Remarkt

Tohave

acontinous

controlwether

ornot

Inthe

mostcases

thevoltage

regulatordid

thegenerator

isworking

whilethe

engineis

failed.Since

theregulator

canonly

berepaired

running,a

controllight

ismounted

onthe

dashin

aBosch

ServiceStation,

changethe

completeboard.

.regulator.

Thischeck

lampshould

lightwhen

theignition

1.Disconnect

groundcable

frombattery.

keyispushed

inand

theengine

isnot

running.2.

Disconnectcable

onvoltage

regulator.The

momentthe

enginestarts

running,the

lightmust

gooff.

Thismeans

thegenerator

is3.

Removeregulator.

workingperfect.

Remark:Is

thelamp

goingon

duringthe

vehicleis

inoperation,

thatwould

meanthe

generatorThe

voltagereguiator

islocated

inthe

frontdoes

notwork.

Thetrouble

mustbe

lookedengine

compartment.after

atonce

toavoid

avoltage

dropin

thebattery.

4.Installation

isdone

vice-versa.

15-3/1

Pre-HeatingSystem

15-4

Checkglow

plugs

Tobe

ableto

havethe

completeglow

systemunder

control,same

isequiped

withaincandescent

spiral.This

spiralmust

getcheery

redwhen

thepie-heater

switchis

broughtinto

positionno.

1.

Ifthe

spiralis

gettingglowing

muchbrighter,

theground

wiremust

bebetter

connectedan

theglow

wire,of

aglow

plug,on

theglow

plugindicator

resistoror

onthe

pie-heatingresistance.

Ifthe

spiralis

notglowing

ataM,

aglow

plugis

outfor

order,mostly

theglow

plugwire

isbroken.

Tocheck

whichone,

proceedas

follows:shorten

outall

glowplugs

oneafter

oneuse

screwdriver

andat

sametime

bringstarter

switchin

pos.1,

theone

glowplug

isout

oforder

onwhich

theglow

plugindicator

isstarting

toglow

whenthe

plugis

shortenedout.

Ifthe

glowplugs

areOK,

checkthe

glowplug

indicatoron

doshboard

orthe

glowplug

indicator

resistorunder

thehood.

Asof

installationof

engineOM

615chassis

no.421

...002229

theouter

busbars

orefunctioning

asresistors.

Therefore,no

resistorin

driverscob.

SeePicture

15-4/1.

Removeand

installglow

plugs

1.Remove

groundcable

terminalfrom

battery.

2.Disconnect

hotwire

fromplug

no.4

andground

cablefrom

plugno.

1.

3.Remove

nutsfrom

plugsand

alsothe

currentconnecting

railswith

insulators.Unscrew

glowplugs.

Remark:I=

Outerbus

baracting

asresistor

2=

Innerbus

bar

Beforeinstalling

glowplugs

again,check

theglow

plugchannel

withtool

no.636589035300

andif

necessaryclean

witha

reamer.

Thereamer

shouldhove

adia.

of11

mm,coat

somewith

greaseand

startthe

toolscrewing

intathe

glowplug

channelto

removethe

carbon.After

flnishing,start

upthe

engineto

havecarbon

blownout.

Picture15-4/2.

4.Install

glowplug

intocylinder

head.

Torqueis5

mkp.

Picture15-4/1

Picture15-4/2

=check

plug636

58903

5300

15-4/1’

Coolinguntis

atengine

20.9

616

Contents

ChapterPage

1General

Technicaldata

coolantpump,

engine616

11/1

Sectionalview

coolantpump,

engine616

1.1/1

Technicaldata

coolantregulator,

engine616

1,1/2

Capacity,engine

6161.1/2

Sectionalview

coolantpump,

engine621,

6361.1/3

Beltpulley-gear

ratios,engine

621,636

1.1/3

Enginecooling

1.1/3

Specialtools

1.2/1

Tighteningtorques

1.2/1

Explodedview

1.3/1

2Checking

coolingsystem

2.1/1

3Repairing

coolantregulator

Removingand

installingcoolant

regulator,engine

6163.1/1

Removingand

installingcoolant

regulator,engine

615,621

3,2/1Removing

andinstalling

coolantregulator,

engine636

3.3/I

4Repairing

coolantpump

Removingand

installingcoolant

pump,engine

615,621,

6364.1/1

Disassemblingand

assemblingcoolant

pump,engine

621,636

4.2/1

5Disassembling

andassembling

fanbearing

Engine615,

621,636

5.1/1

6Cleaning

coolingsystem

6.1/1

UKO

3040221

03-06

General20.9

616

Technicaldata

Enginecooling

Parallel-distanceof

fanfrom

radiatorblock

mm

15

Distance,flange

-hub

amm

89.2–

0.2

Distance,impeVer

-flange

bmm

23–

0.2

Coolantpump,

alternatorand

crankshaft

V-belttension

Aircompressor

andcrankshaft

Coolantpump

andfan-bearing

bracket

mm

approx.5

to10*

mm

approx.10

to15

mm

approx.10

to15*

Gearratio

fromCoolant

pumpAlternator

Fannormal

tropicscrankshaft

to1:0.9

1:1.951:1

1:1,1

Depressingwith

moderatethumb

pressure

Coolantpump

1Hub

2Deep-groove

ballbearing

3Bearing

housing4

Slidering

seat5

Counterring

with0

Ring

6Impeller

7Coolant

shattpump

aRelerence

sizeb

Distanoeimpeller

-flange

7

UKD30402

2103-06

1.1/1

General20.9

Coolantpump

Distancea

89-0.2Reference

sizeb

23–

0.2;Installation

dim.C=

14.7;

1Hub

2=

Radialseal

3Sealing

ringretainer

4=Deep-groove

ballbearing

5=Spacer

sleeve

6=Retaining

ring7=Deep-groove

ballbearing

8Sealing

ring9=

Bearinghouse

10=

Slidering

seal11

=Counter

ring

12=

0-ring13

=Impeller

14=Coolant

shaftpump

15=

Oiltillerscrew

withvent

bore16

=Oil

level-inspectionscrew

Beltpulley-gear

ratios

Gearratio

fromCrankshaft

toCoolant

pumpAlternator

Fan

DM621-Typ421

1:0.91:1.95

1:1

0M636-Typ4ll1:1.18

11.72

1:1

Enginecooling

DesignationTyp

421/ OM

621Typ

411/DM636

Note

Parallel-distanceof

fanfrom

radiatorblock

15mm

10mm

-

Distanceof

impellerfrom

flangeof

coolantpump

23–

0.223

–0.2

Ca.5-10mm

Ca.6mm

Depressingwith

moderatethumb

pressure

V-belttension

atcoolant

pump,alternator

andcrankshaft

V-belttension

atair

compressorand

crankshaftCa.

10-15mmCa.

10-15mmDepressing

withmoderate

thumbpressure

V-belttension

atcoolant

pumpand

fan-bearingpedestal

Ca.10-15mm

-Depressing

withmoderate

thumbpressure

621636

IsA-B

16

1234

55789/011121314

d

uz2o-0o15

d=

Oillevel

UKD30

40221

03-061.1/3

General20.9

Specialtools

-Designation

Thread/strength

Nm

Coolantpump

atcrankcase

M8/10.9

30

Coolantpump

housingat

bearinghousing

M6

10

Fanat

hubM

8/8.825 616

Tighteningtorques

uKo3040221

03-081.2/1

ExplodedView

GeneralInformation

469

71a

64

7366

3Coolant

pump44

Hollowbolt

5Grooved

ballbearing

46Sealing

ring7

Impeller50

Hose9

Thrustring

53Gasket

11Sealing

ring55

Washer13

Sealingring

57Connection

piece16

Hub60

Fan18

Gasket62

Holder20

Bolt64

Ballbearing

23Prepare

set66

Disk25

V-belt69

Springlock

washer27

V-belt71

Bolt30

Springlock

washer73

Circlip31

Bolt75

Beltpulley

34Gasket

80Bolt

36Washer

82Washer

38Bolt

84Spacer

40Washer

86V-belt

43Vent

line88

V-belt

20.9

616

‘5O a

55

0I8213

UZ20-0014

EngineCooling

UKD30

40221

03-061.3/1

CheckingCooling

system20.9

Checking

Thecooling

systemoperates

atoverpressure

controlledby

thevalve

inthe

inletlock

ofthe

expansiontank.

Whenthe

coolantis

heated,the

overpressurevalve

maintainsthe

systemunder

pressureup

to0.5

kp/cm2while

thevacuum

valvebalances

anyharmful

vacuumduring

cooling.The

pressurizedcooling

systemmust

thereforebe

checkedfor

leakswhen

cold.

1Unscrew

closingcover

fromexpansion

tank.

2For

checking,top

upcoolant

tomaximum

levelso

thattoomuch

airdoesnot

requireto

becompressed.

3Fit

specialtool

No.1.

4Pump

upto

approx.0.5

km/cm2with

testpump

andcheck

whetherpressure

remainsstationary.

Ifthere

isapressure

drop,repair

defectpoints.

Evenif

pressureremains

stationary,check

hoseconnec

tionsfor

needlehole

leakssweating.

Thefollowing

characteristicsmay

occur:

5If

thepointer

onthe

testerfluctuates,

thisis

usuallyan

indicationthat

thecylinder

headgasket

isleaking.

6Loss

ofcoolant

viathe

overflowpipe

isindicated

byasudden

riseand

thenadrop

inthetest

pressure.This

canbe

causedby

furringin

thewater

jacket,caused

bylocal

hotspots

whichresult

insteam

bubblesbeing

formedand

waterthus

beingejected.

Torectify,

haveengine

orentire

coolingsystem

defurred.

7Test

closingcover

withspecial

toolNo.

1.In

particular,checksealing

ringfor

notchesor

cracking.

616

1!UR

500004

UKD

30402

2103-08

2.1/1

Removaland

Installationof

CoolantRegulator

20.9

Removal

1Drain

coolant.

2Disconnect

bypassline

fromengine

tocoolant

regulator.

3Disconnect

lineto

coolantpump.

4Disconnect

lineto

radiatorand

removecoolant

regulator.

5Clean

allparts,

checkand

replaceas

necessary.

6Check

regulatorinsert

forfunction,

referto

1.1/2.

7Installation

takesplace

inthe

reversesequence.

8Fill

incoolant.

Referto

1.1/2for

capacities.

616

OR50-007111

UKD3040221

03-063.1/1

Removingand

installingcoolant

regulator20,9

Removaland

installation

1Drain

coolant.With

antifreezecollect

contents.Drain

plugis

underneaththe

radiator.

2Remove

uppercoolant

hoseof

coolantregulator.

3Unscrew

pipesockets

andremove

gasket.

4Remove

regulatorelement.

Important!When

reinstalling,the

ventvalve

borefor

radiatormust

belocated

onthe

sideof

thecoolant

connection,

i.e.at

thehighest

point.

Mainvalve

closedBy-pass

valvefully

openedStroke

b7.5

to8mm

1000lanI

regulator2

SeatIngring

3Hexagon

socketscrew

4Cover

SBait

vaive6

Coolantregulator

element7

Screwplug

Afrom

engineB

toengine

viaby.pass

line

5Check

regulatorelement

forfunction

and,if

required,exchange.

Thecoolant

regulatoris

besttested

ina

containerwith

hotwater

inwhich

athermometer

isimmersed.The

regulatorshouldbegin

toopenat

79°+

10Cand

entirelyopen

at91

°+3°

C.

Mainvalve

openedStroke

a8to9

mm

atapprox.

91°to

94°C.By-pass

lineclosed

Afrom

engineS

10radiator

Apressure

reliefvalvein

thecoolant

expansiontank

connectionensures

anoverpressure

of0.4

barin

thesystem.

Consequentlythe

boilingtemperature

isincreased

insea

levelfrom

1000to

108°C.

Note:Repairs

cannotbe

madeto

theregulator

element.Unusable

regulatorelements

areto

bereplaced.

6Installation

takesplace

inreverse

sequence.

7Fill

withcoolant.

Runengine

andcheck

hoseconnections

forleaks.

Replacehose

clampand

rubberhoses,

if required.

Note:The

coolingwater

contentsin

engineand

originalradiator

isspecified

forthe

maximumload

ofengine

forexample

highoutside

temperatures,mountai

nousarea.

615621

-5

1-

A

B-

UKO3040221

03-063.2/1

Removingand

installingcoolant

regulator20.9

636

Removaland

installation

1Drain

coolant.With

antifreezecollect

contents.Drain

cockis

atthe

lowercoolant

line.

2Release

hoseclamp

andhose

ofcoolant

linefrom

reservoirto

engineand

remove.

3Release

unionnut

knurlednut

andremove

withthe

coolantregulator.

Payattention

torubber

gasketwhich

isin

frontof

thebead

ofthe

coolantregulator.

Thearrow

embossedon

thecoolant

regulatormust

alwayspoint

upwardwhen

installing,i.

e.toward

expansiontank.

Coatunion

nutor

threadedring

beforethe

installationwith

grease.

Note:Repairs

cannotbe

madeto

thecoolant

regulatorfor

exampleby

exchangingthe

insert.Unusable

coolantregulators

areto

bereplaced,

recognizablefrom

fullopening

incold

condition.Acoolant

regulatoris

besttested

ina

containerwith

hotwater

inwhich

athermometer

isimmersed,

Thethermostat

shouldbegin

toopen

at80°-13°

andentirely

openat

87°to

88°.At

thesame

timethe

valveshould

riseby

8mm.Apressure

reliefvalveinthe

coolantexpansion

tankconnection

ensuresan

overpressureof

0.4bar.

Consequentlythe

boilingtemperature

isincreasedat

sealevel

from1000

to108°

C.

4Installation

takesplace

inreverse

sequence.

5Fill

withcoolant.

Runengine

andcheck

hoseconnections

forleaks.Ifrequired,

replacehose

clampand

rubberhoses.

UKD

30402

210306

3.3/1

Removingand

installingcoolant

pump20.9

615621636

Removaland

installation

A.With

engineOM

615and

OM

621B.

Withengine

OM

636

1Drain

coolant.Ifcoolant

containsadditives,

col-1

Draincoolant.

Collectin

thecase

ofantifreeze.

lectcoolant.

2Remove

v-belt.2

Removebelt

tensionerfor

aircompressor.

3Unscrew

fasteningbolts

ofthe

coolantpump

at3

Releaseupper

radiatormount.

thecylinder

head.Remove

coolantpump.

Notegasket.

4Unscrew

bracketat

theengine

block.4

Installationtakes

placein

reversesequence.

5Release

aridremove

v-beltfor

fandrive.

5Set

v-beltto

correcttension,

i.e.,so

thatitcan

6Release

tensioningdevice

ofthe

alternatorand

justbe

pressedwith

thethumb

outof

thestraight

remove.Values

accordingto

tableon

page1.1/3.

7Release

bothhose

linesat

pipesocket

ofcoolant

pumphousing.

8Unscrew

slidering

seal.

9Unscrew

coolantpump

threehexagon

bolts.

10Replace

gasketand

sealingring

betweencoo

lantpump

andcrankcase.

Before,thoroughly

cleanparting

surfaceof

sealingcompound

residues.

11Installation

takesplace

inreverse

sequence.

12Installthe

slidering

sealfree

oftension

anduse

thetwo

newsealing

ringsat

theconnections.

13Fill

withcoolant,

Runengine

andcheck

hoseconnections

aswell

asflange

connectionofpump

atengine

blockfor

leaks.

Note:In

orderto

determinewhether

thepump

correctlyworks

afterinstallation,

takeclosing

coverat

coolantfilterpipeoffwith

runningwarm

engine.The

flowmust

alreadybe

visiblewhen

engineis

idling.

UKD

3040221

03-064.1/1

Disassemblingand

assemblingcoolant

pump20.9

621636

Thecoolant

pumpversion

onengine

GM

621has

aio

Withthe

versiononOM

621,press

counterring

slidering

sealbetween

bearinghousing

andimpeller,

intoimpeller

withrubber

0-mgafter

lightlyoiling

Thecoolant

pumpversion

onengine

OM

636has

arubber

0-ring.collector ring

gasket.The

repairin

bothcoolant

pumpversion

isthe

sameby

analogy.Note:

Lappedside

ofcounter

ringmust

pointupward

towardslip

ringgasket

andmust

notbe

damagedDisassembly

whenpressing

in.

11Press

sealingring

intobearing

housingwith

1Unscrew

coolantpump

housingfrom

bearingassembly

sleeve.housing.

Beforehand,lightly

coatoutside

ofsealing

ringand

2Pulloffhuborbeltpulleyfromcoolantpumpshaft

barein

bearinghousing

withoil.

withextractor

112589

0733

00.To

doso,

thecoolant

pumptshaft

isheldina

vicewith

theimpeller.

12On

theversion

OM

621,press

slipring

gasketinto

bearinghousing

withsuitable

installersleeve.

3Pullthe

sealingring

retainerwith

anextractor

offCoat

boreof

housingwith

oilbeforehand.

thebearing

housing.Then

pressthe

sealingring

outof

thesealing

ringretainer.

13For

versiononOM

636slip compression

spring,cover,

slipring

cage,sealing

ringand

slipring

onto4

Pressthe

coolantpump

shaftwith

adrift

outof

shaft.the

bearinghousing.

Afterassembly,

checkwhether

thecover

inproperly

seat