CLAAS Engine Mercedez-Benz OM502LA Repair Manual – PDF DOWNLOAD

Description

CLAAS Engine Mercedez-Benz OM502LA Repair Manual – PDF DOWNLOAD

DESCRIPTION:

CLAAS Engine Mercedez-Benz OM502LA Repair Manual – PDFDOWNLOAD

Handling the manual :

This repair manual should help you to maintain ongoing operational capacity. The high value of the harvesting machine is ensured through careful maintenance and technical monitoring by customer service. This repair manual is a compilation of our service technicians’ and shop-floor experience. The picture sequence demonstrates the steps in a repair procedure.

• The text provides you with the information required for making adjustments, using special tools and further similar information. Essential repairs are listed in such a way that even individual and small repairs can be easily found and followed.
• Supplements are added to reflect the ongoing technical development of the machines and the manual is thereby continuously being updated as a reference book. As a precaution, always compare the setting values and fill quantities with the most recent operator’s manual and the technical systems documents for the respective machine.

TABLE OF CONTENTS:

CLAAS Engine Mercedez-Benz OM502LA Repair Manual – PDF DOWNLOAD

Mercedes-Benz OM502LA............................................................................................................................  1
Table of contents................................................................................................................................  3
Introduction.....................................................................................................................................  4
	General Information..........................................................................................................................  4
		Validity of manual.......................................................................................................................  4
		Handling the manual......................................................................................................................  4
			Texts and figures....................................................................................................................  4
			Document structure based on the assembly structure...................................................................................  5
			Search and find......................................................................................................................  5
			Directions...........................................................................................................................  5
			Abbreviations........................................................................................................................  6
			Technical terms......................................................................................................................  7
	General repair instructions..................................................................................................................  8
		Technical specifications.................................................................................................................  8
		Information on proper repairs............................................................................................................  8
		Self-locking bolts.......................................................................................................................  8
		Liquid locking compound..................................................................................................................  8
		Steel roller chains......................................................................................................................  9
			Tensioning...........................................................................................................................  9
			Chain connector......................................................................................................................  9
		Taper ring fasteners..................................................................................................................... 10
			Dismounting.......................................................................................................................... 10
			Installation......................................................................................................................... 10
		Gib head key joints...................................................................................................................... 11
			Dismounting.......................................................................................................................... 11
			Installation......................................................................................................................... 11
		Lock collar bearing...................................................................................................................... 12
			Dismounting.......................................................................................................................... 12
			Installation......................................................................................................................... 12
		Adapter sleeve bearings.................................................................................................................. 13
			Dismounting.......................................................................................................................... 13
			Installation......................................................................................................................... 13
		Chuck bushing............................................................................................................................ 13
			Dismounting.......................................................................................................................... 13
			Installation......................................................................................................................... 14
		Circlips................................................................................................................................. 15
		Ferrule fittings......................................................................................................................... 16
			Screwing in.......................................................................................................................... 16
			Non-tight ferrule connection......................................................................................................... 16
		Sealing cone fittings.................................................................................................................... 17
		Hydraulic hoses.......................................................................................................................... 17
			Hose placement....................................................................................................................... 18
		Treatment of sealing faces............................................................................................................... 19
		Spare parts.............................................................................................................................. 19
	Torque settings.............................................................................................................................. 20
		Tightening torques for metric standard threads........................................................................................... 20
		Tightening torques for metric fine thread screws......................................................................................... 21
		Tightening torques for hydraulic screw fittings and air conditioner screw fittings with sealing cone and O-ring according to DIN 3865.... 22
		Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861....................................................... 23
		Tightening torques for SDS hydraulic male connectors..................................................................................... 24
		Tightening torques for hydraulic swivel fittings......................................................................................... 27
		Tightening torques for hollow screws DIN 7643............................................................................................ 28
		Tightening torques for direction-adjustable SDE hydraulic male connectors................................................................ 29
		Tightening torques for brake line screw fittings......................................................................................... 31
		Tightening torques for worm drive hose clamps............................................................................................ 31
		Tightening torque for spring-loaded worm drive hose clamps............................................................................... 31
CCN explanation.................................................................................................................................. 32
	CCN (CLAAS Component Number)................................................................................................................. 32
		General.................................................................................................................................. 32
		Electric systems standard................................................................................................................ 32
		Hydraulic system standard................................................................................................................ 33
CCN (CLAAS Component Number)..................................................................................................................... 34
	A............................................................................................................................................ 35
	B............................................................................................................................................ 35
	G............................................................................................................................................ 35
	M............................................................................................................................................ 35
	R............................................................................................................................................ 35
	Y............................................................................................................................................ 35
Safety........................................................................................................................................... 36
	General Information.......................................................................................................................... 36
		Of special importance.................................................................................................................... 36
		Identification of warning and danger signs............................................................................................... 36
		Regulations for avoiding accidents with personal injuries................................................................................ 37
			General.............................................................................................................................. 37
			Testing, adjusting and repair work................................................................................................... 37
			Engine operation..................................................................................................................... 38
			Suspended loads...................................................................................................................... 38
			Working on piping and hoses.......................................................................................................... 39
			Working on the electric system....................................................................................................... 39
			Working on the hydraulic system...................................................................................................... 40
			Electric welding..................................................................................................................... 41
			Painting work........................................................................................................................ 41
			Working with urea solution........................................................................................................... 41
		Information on how to avoid damage and premature wear.................................................................................... 42
			General.............................................................................................................................. 42
		Liability limitation..................................................................................................................... 42
			General.............................................................................................................................. 42
			Shutting down and storage............................................................................................................ 43
		Regulations for avoiding health and environmental damage................................................................................. 43
			Precautionary measures for protection against health and environmental damage........................................................ 43
			Disposal of operating utilities and auxiliary operating utilities.................................................................... 43
		Information for working on the diesel engine............................................................................................. 43
			Accident protection.................................................................................................................. 43
			Cleanliness.......................................................................................................................... 44
			Installation instructions............................................................................................................ 45
			Engine overhaul...................................................................................................................... 45
				Putting into operation after an engine overhaul.................................................................................. 46
		First aid measures....................................................................................................................... 46
01 Engine........................................................................................................................................ 47
	0102 Complete component...................................................................................................................... 47
		Type design.............................................................................................................................. 47
		Engine data.............................................................................................................................. 47
		Engine description....................................................................................................................... 48
			Engine components.................................................................................................................... 48
			Sensors.............................................................................................................................. 50
			Ignition order....................................................................................................................... 52
		Cranking the engine...................................................................................................................... 53
			Special tool for built-in engine..................................................................................................... 54
			Special tools for removed engine..................................................................................................... 55
			Cranking the engine in built-in condition............................................................................................ 56
				JAGUAR........................................................................................................................... 56
				LEXION........................................................................................................................... 58
			Cranking the engine in removed condition............................................................................................. 60
	0105 Engine suspension....................................................................................................................... 61
		Lifting eyes............................................................................................................................. 62
			Technical specifications............................................................................................................. 62
	0110 Engine housing.......................................................................................................................... 63
		Oil sump................................................................................................................................. 64
			Special tool......................................................................................................................... 64
			Technical specifications............................................................................................................. 65
			Removal.............................................................................................................................. 65
			Installation......................................................................................................................... 67
		Crankshaft front seal.................................................................................................................... 69
			Special tool......................................................................................................................... 69
			Technical specifications............................................................................................................. 70
			Removing the radial seal............................................................................................................. 70
			Installing the radial seal........................................................................................................... 72
			Removing the cassette seal........................................................................................................... 72
			Installing the cassette seal ring.................................................................................................... 74
		Crankshaft rear seal..................................................................................................................... 75
			Special tool......................................................................................................................... 75
			Technical specifications............................................................................................................. 76
			Removal.............................................................................................................................. 76
			Installation......................................................................................................................... 77
		Crankcase cover.......................................................................................................................... 79
			Special tool......................................................................................................................... 79
			Technical specifications............................................................................................................. 80
			Removal.............................................................................................................................. 80
			Installation......................................................................................................................... 81
		Timing housing cover..................................................................................................................... 82
			Special tool......................................................................................................................... 82
			Technical specifications............................................................................................................. 83
			Removal.............................................................................................................................. 83
				Applies to design type 942.993................................................................................................... 84
			Installation......................................................................................................................... 85
				Applies to design type 942.993................................................................................................... 86
		Timing housing........................................................................................................................... 88
			Work preparation..................................................................................................................... 88
			Technical specifications............................................................................................................. 89
			Removal.............................................................................................................................. 90
			Installation......................................................................................................................... 91
		Timing housing........................................................................................................................... 93
			Work preparation..................................................................................................................... 93
			Technical specifications............................................................................................................. 94
			Removal.............................................................................................................................. 94
			Installation......................................................................................................................... 96
	0115 Engine unit............................................................................................................................. 99
		Piston...................................................................................................................................100
			Special tool.........................................................................................................................100
			Technical specifications.............................................................................................................102
			Removal..............................................................................................................................103
			Removal..............................................................................................................................105
			Disassembly..........................................................................................................................107
			Checking.............................................................................................................................108
			Assembly.............................................................................................................................109
			Installation.........................................................................................................................110
			Installation.........................................................................................................................111
			Measuring the excess dimension.......................................................................................................113
		Connecting rod...........................................................................................................................114
			Technical specifications.............................................................................................................114
			Removal..............................................................................................................................115
			Checking.............................................................................................................................115
			Installation.........................................................................................................................116
		Cylinder liner...........................................................................................................................117
			Special tool.........................................................................................................................117
			Technical specifications.............................................................................................................119
			Removal..............................................................................................................................120
			Checking.............................................................................................................................121
			Installation.........................................................................................................................122
				Applies to design type: 458.99x..................................................................................................123
			Measuring the excess dimension.......................................................................................................123
			Measuring the cylinder bore..........................................................................................................124
		Crankshaft...............................................................................................................................125
			Special tool.........................................................................................................................125
			Technical specifications.............................................................................................................127
			Removal..............................................................................................................................129
			Checking.............................................................................................................................131
			Installation.........................................................................................................................135
		Crankshaft ring..........................................................................................................................138
			Special tool.........................................................................................................................138
			Technical specifications.............................................................................................................139
			Removal..............................................................................................................................139
			Installation.........................................................................................................................140
		Oscillation damper.......................................................................................................................141
			Special tool.........................................................................................................................141
			Technical specifications.............................................................................................................142
			Removal..............................................................................................................................142
			Installation.........................................................................................................................143
		Flywheel.................................................................................................................................145
			Special tool.........................................................................................................................145
			Technical specifications.............................................................................................................147
			Removal..............................................................................................................................148
			Checking.............................................................................................................................149
			Installation.........................................................................................................................149
			Replace ring gear....................................................................................................................150
			Replacing the ring...................................................................................................................151
	0120 Cylinder head / Valves / Idler gear.....................................................................................................153
		Valve cover..............................................................................................................................154
			Technical specifications.............................................................................................................154
		Cylinder head............................................................................................................................155
			Special tool.........................................................................................................................155
			Technical specifications.............................................................................................................156
			Removal..............................................................................................................................158
			Checking.............................................................................................................................159
			Disassembly..........................................................................................................................160
			Assembly.............................................................................................................................161
			Installation.........................................................................................................................161
		Rocker lever.............................................................................................................................163
			Special tool.........................................................................................................................163
			Technical specifications.............................................................................................................164
			Installation instructions............................................................................................................165
			Replacing the roller tappets.........................................................................................................165
		Valves...................................................................................................................................166
			Special tool.........................................................................................................................166
			Technical specifications.............................................................................................................167
			Installation instructions............................................................................................................168
			Checking the valves..................................................................................................................168
			Adjusting the valve lash.............................................................................................................169
		Valve springs and valve stem seals.......................................................................................................171
			Special tool.........................................................................................................................171
				Mercedes-Benz....................................................................................................................172
				MAN..............................................................................................................................172
			Technical specifications.............................................................................................................173
			Removal..............................................................................................................................173
			Installation.........................................................................................................................174
		Valve guide..............................................................................................................................176
			Work preparation.....................................................................................................................176
			Special tool.........................................................................................................................176
			Technical specifications.............................................................................................................177
			Checking.............................................................................................................................178
			Removal..............................................................................................................................179
			Installation.........................................................................................................................179
		Camshaft.................................................................................................................................181
			Special tool.........................................................................................................................181
			Technical specifications.............................................................................................................182
			Removal..............................................................................................................................182
			Checking.............................................................................................................................183
			Installation.........................................................................................................................184
	0125 Injection - / Fuel system...............................................................................................................186
		Fuel system..............................................................................................................................187
		Cylinder head injection line.............................................................................................................189
			Special tool.........................................................................................................................189
			Technical specifications.............................................................................................................190
			Installation instructions............................................................................................................190
		Cylinder head leakage lines..............................................................................................................192
			Technical specifications.............................................................................................................192
		Nozzle holder combination................................................................................................................193
			Special tool.........................................................................................................................193
			Technical specifications.............................................................................................................195
			Removal..............................................................................................................................196
			Installation.........................................................................................................................197
		Protective sleeve........................................................................................................................199
			Special tool.........................................................................................................................199
			Technical specifications.............................................................................................................200
			Installation instructions............................................................................................................200
		Plug-on pump.............................................................................................................................202
			Special tool.........................................................................................................................202
			Work preparation.....................................................................................................................202
			Technical specifications.............................................................................................................203
			Removal..............................................................................................................................204
			Installation.........................................................................................................................204
		Fuel pump................................................................................................................................207
			Work preparation.....................................................................................................................207
			Technical specifications.............................................................................................................208
			Removal..............................................................................................................................209
			Installation.........................................................................................................................209
		Fuel filter housing......................................................................................................................211
			Technical specifications.............................................................................................................211
	0130 Lubricating oil system..................................................................................................................212
		Lubricating oil system...................................................................................................................213
			Special tool.........................................................................................................................213
			Pre-filling..........................................................................................................................214
		Oil spray nozzle.........................................................................................................................216
			Technical specifications.............................................................................................................216
			Installation instructions............................................................................................................217
		Oil filter housing.......................................................................................................................218
			Work preparation.....................................................................................................................218
			Technical specifications.............................................................................................................219
			Removal..............................................................................................................................220
			Installation.........................................................................................................................222
		Oil cooler...............................................................................................................................225
			Technical specifications.............................................................................................................225
			Installation instructions............................................................................................................225
		Oil excess pressure valve................................................................................................................226
			Technical specifications.............................................................................................................226
			Installation instructions............................................................................................................226
		Oil pump.................................................................................................................................227
			Technical specifications.............................................................................................................227
			Installation instructions............................................................................................................227
	0135 Cooling system..........................................................................................................................229
		Coolant..................................................................................................................................230
			Special tool.........................................................................................................................230
			Technical specifications.............................................................................................................231
			Draining.............................................................................................................................231
			Filling up...........................................................................................................................232
			Cleaning the coolant circuit.........................................................................................................232
		Coolant pump.............................................................................................................................234
			Special tool.........................................................................................................................234
			Technical specifications.............................................................................................................235
			Removal..............................................................................................................................236
			Disassembly..........................................................................................................................237
			Assembly.............................................................................................................................238
			Installation.........................................................................................................................239
		Coolant thermostat.......................................................................................................................241
			Work preparation.....................................................................................................................241
			Technical specifications.............................................................................................................242
			Removal..............................................................................................................................242
			Checking.............................................................................................................................244
			Installation.........................................................................................................................244
	0140 Exhaust system..........................................................................................................................246
		Exhaust manifold.........................................................................................................................247
			Technical specifications.............................................................................................................248
			Removal..............................................................................................................................248
			Installation.........................................................................................................................250
		Exhaust manifold.........................................................................................................................252
			Technical specifications.............................................................................................................253
			Removal..............................................................................................................................253
			Installation.........................................................................................................................255
		Main exhaust manifold....................................................................................................................257
			Technical specifications.............................................................................................................257
			Installation instructions............................................................................................................258
		Exhaust turbo charger suction tube.......................................................................................................259
			Technical specifications.............................................................................................................259
			Installation instructions............................................................................................................260
		Exhaust turbo charger....................................................................................................................261
			Special tool.........................................................................................................................261
			Technical specifications.............................................................................................................262
			Removal..............................................................................................................................263
			Installation.........................................................................................................................264
			Checking.............................................................................................................................266
				Checking the axial play..........................................................................................................267
				Checking the radial play.........................................................................................................267
		Exhaust turbo charger....................................................................................................................268
			Special tool.........................................................................................................................268
			Technical specifications.............................................................................................................269
			Removal..............................................................................................................................270
			Installation.........................................................................................................................272
			Checking.............................................................................................................................273
				Checking the axial play..........................................................................................................274
				Checking the radial play.........................................................................................................274
		Catalyst.................................................................................................................................275
			Work preparation.....................................................................................................................275
			Technical specifications.............................................................................................................276
			Installation instructions............................................................................................................276
	0145 Air intake..............................................................................................................................278
		Intake housing...........................................................................................................................279
			Technical specifications.............................................................................................................279
			Removal..............................................................................................................................280
				Applies to type designs with one exhaust turbo charger...........................................................................280
				Applies to type designs with two exhaust turbo chargers..........................................................................281
			Installation.........................................................................................................................282
				Applies to type designs with two exhaust turbo chargers..........................................................................283
				Applies to type designs with one exhaust turbo charger...........................................................................283
	0150 Engine attachment parts.................................................................................................................284
		Electric starting motor..................................................................................................................285
			Work preparation.....................................................................................................................285
			Technical specifications.............................................................................................................286
			Removal..............................................................................................................................287
			Installation.........................................................................................................................287
			Removing the solenoid switch.........................................................................................................288
			Installing the solenoid switch.......................................................................................................289
			Removing the starter pinion..........................................................................................................290
			Installing the starter pinion........................................................................................................291
		Alternator...............................................................................................................................293
			Special tool.........................................................................................................................293
			Technical specifications.............................................................................................................294
			Removal..............................................................................................................................294
			Installation.........................................................................................................................295
			Removing the pulley..................................................................................................................296
			Installing the pulley................................................................................................................297
		Alternator...............................................................................................................................298
			Special tool.........................................................................................................................298
			Technical specifications.............................................................................................................299
			Removal..............................................................................................................................300
				Alternator (G002)................................................................................................................300
				Alternator (G002)................................................................................................................300
				Alternator (G003)................................................................................................................300
				Alternator (G003)................................................................................................................301
				Alternator (G003)................................................................................................................301
			Installation.........................................................................................................................301
				Alternator (G002)................................................................................................................301
				Alternator (G002)................................................................................................................302
				Alternator (G003)................................................................................................................302
				Alternator (G003)................................................................................................................302
				Alternator (G003)................................................................................................................302
			Removing the pulley..................................................................................................................303
			Installing the pulley................................................................................................................303
		Alternator drive belt tensioner..........................................................................................................304
			Technical specifications.............................................................................................................304
			Installation instructions............................................................................................................304
		Air compressor...........................................................................................................................306
			Special tool.........................................................................................................................306
			Technical specifications.............................................................................................................308
			Checking the oil thrown out..........................................................................................................309
			Removing the drive wheel.............................................................................................................311
			Installing the drive wheel...........................................................................................................312
			Removing the cylinder head...........................................................................................................313
				Applies to design type 942.993...................................................................................................314
			Disassembling the cylinder head......................................................................................................315
			Assembling the cylinder head.........................................................................................................315
			Installing the cylinder head.........................................................................................................316
				Applies to design type 942.993...................................................................................................317
			Removing the piston and the cylinder liner...........................................................................................318
			Installing the piston and the cylinder liner.........................................................................................318
			Removing the crankshaft and the connecting rod.......................................................................................319
			Installing the crankshaft and connecting rod.........................................................................................321
	0155 Engine control..........................................................................................................................324
		MR/PLD control unit......................................................................................................................325
			Technical specifications.............................................................................................................325
			Installation instructions............................................................................................................325
	0165 Exhaust gas treatment...................................................................................................................327
		Exhaust treatment system.................................................................................................................328
			Work preparation.....................................................................................................................328
			Special tool.........................................................................................................................328
			Technical specifications.............................................................................................................330
			Checking the urea solution (purity)..................................................................................................331
			Checking the urea solution (density).................................................................................................332
		Urea heater valve........................................................................................................................333
			Work preparation.....................................................................................................................333
			Special tool.........................................................................................................................333
			Technical specifications.............................................................................................................334
			Removal..............................................................................................................................334
			Installation.........................................................................................................................335
		Urea pump................................................................................................................................336
			Work preparation.....................................................................................................................336
			Special tool.........................................................................................................................336
			Technical specifications.............................................................................................................337
			Removal..............................................................................................................................338
			Installation.........................................................................................................................339
			Removing the pressure accumulator....................................................................................................341
			Installing the pressure accumulator..................................................................................................341
			Removing the dump valve..............................................................................................................341
			Installing the dump valve............................................................................................................343
			Removing the intake filter...........................................................................................................344
			Installing the intake filter.........................................................................................................345
			Checking the electric wiring loom....................................................................................................345
			Filling the accumulator..............................................................................................................346
		Urea dosing unit.........................................................................................................................347
			Work preparation.....................................................................................................................347
			Special tool.........................................................................................................................347
			Technical specifications.............................................................................................................349
			Installation instructions............................................................................................................350
			Flushing.............................................................................................................................350
		Urea injector............................................................................................................................353
			Technical specifications.............................................................................................................353
			Installation instructions............................................................................................................353
	0190 Accessories.............................................................................................................................354
		Engine insulation........................................................................................................................355
			Work preparation.....................................................................................................................355
			Technical specifications.............................................................................................................356
			Removal..............................................................................................................................356
			Removal..............................................................................................................................362
		Engine insulation........................................................................................................................368
			Work preparation.....................................................................................................................368
			Technical specifications.............................................................................................................369
			Removal..............................................................................................................................369
			Installation.........................................................................................................................372
Index............................................................................................................................................376
	A............................................................................................................................................376
	B............................................................................................................................................376
	C............................................................................................................................................376
	D............................................................................................................................................378
	E............................................................................................................................................378
	F............................................................................................................................................379
	H............................................................................................................................................379
	I............................................................................................................................................379
	L............................................................................................................................................379
	M............................................................................................................................................380
	N............................................................................................................................................380
	O............................................................................................................................................380
	P............................................................................................................................................380
	R............................................................................................................................................381
	S............................................................................................................................................382
	T............................................................................................................................................383
	U............................................................................................................................................383
	V............................................................................................................................................384
	W............................................................................................................................................384

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CLAAS ENGINE MERCEDEZ-BENZ OM502LA REPAIR MANUAL – PDF DOWNLOAD:

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