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
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
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