Test values

00 Overall bus
Brake calculation pressure
Test values
Brake calculation pressure 9 bar
Brake pressure reserve
Test values
Brake pressure reserve, circuit 1 10 bar
Brake pressure reserve, circuit 2 10 bar
Pressure regulator
Test values
Pressure regulator cutoff pressure: 12±0,3 bar
Pressure regulator switching range 1,5±0,25 bar
Four-circuit safety valve
Test values
Opening pressure, circuit 1 and 2 9-0,3 bar
Opening pressure, circuit 3 and 4 7,5-0,3 bar
Closing pressure, circuit 1 and 2 min 7 bar
Closing pressure, circuit 3 and 4 min 4,5 bar
Steering mechanical system
Test values
Permissible axial play of the track rod pivots max. 2 mm
Permissible steering play on steering wheel circumference
(measured on the circumference of the steering wheel with engine
running and in the straight-ahead position) max. 40 mm
01 Engine
Cylinder liner
Test values
Code letter A :
101,985...101,991 mm
Code letter B :
Cylinder barrel or cylinder liner inner diameter
101,992...102,008 mm
Code letter C :
102,009...102,015 mm
Cylinder barrel deviation of cylinder form max. 0,012 mm
upper reversal point of the
first piston ring : max. 0,1
Wear of cylinder barrel or cylinder liner measured in direction of
mm
travel or lateral direction
in the centre of the barrel :
max. 0,05 mm
Compression
 Test values
Compression at starter speed min 28 bar
Permissible difference between the individual cylinders max. 4 bar
Engine block

W01_40-0002-06
No. Test values
Standard : 298,35...298,5
mm
Measurement -0.3 mm :
298,05...298,2 mm
A Cylinder crankcase height
Measurement -0.6 mm :
297,75...297,9 mm
Measurement -0.9 mm :
297,45...297,6 mm
B Bore diameter for cylinder liner in cylinder crankcase 106...106,035 mm
C Bore diameter for cylinder liner collar in cylinder crankcase 109,572...109,626 mm
Distance between cylinder liner collar seat and crankshaft
D
bearing cap mating surface in all levels of installation 338,9...339,1 mm
Surface roughness (Rz) of drilled (honed) cylinder bore for
installation of cylinder liners 25 µm
Concentricity : max. 0,03
Surface of cylinder liner collar in the cylinder crankcase mm
Flatness : max. 0,01 mm
 Surface roughness (Rz)
: 16 µm
Roundness : max. 0,06 mm
Bore for the cylinder liner collar in the cylinder crankcase Surface roughness (Rz)
: 25 µm
Overlap of cylinder liner with machined cylinder crankcase max. 0,04 mm
Transition radius from cylinder liner collar diameter to cylinder
E
liner collar seat in the cylinder crankcase max. 0,2 mm
0,3...0,4 mm
F Chamfer on the cylinder liner collar seat of cylinder bore
45°
Cylinder head

M01_00-0057-01
No. Test values
L Shank length of the cylinder head bolt max. 151 mm
Permissible deviation from flatness on the cylinder head
mating surface (over the entire length) max. 0,07 mm
Permissible deviation from flatness on the cylinder head
mating surface (over a length of 150 mm) max. 0,02 mm
Permissible deviation from flatness on the cylinder crankcase
mating surface (over the entire length) max. 0,03 mm
Permissible deviation from flatness on the cylinder crankcase
mating surface (Over a length of 150 mm in longitudinal or
transverse directions) max. 0,015 mm
New : 107,9...108,1 mm
Height of cylinder head after material removal : min
106,9 mm
Valve bridge guide pin protrusion from cylinder head 25,1...25,5 mm
Surface roughness (Rz) of cylinder head mating surface 8...16 µm
03 Power unit
Flywheel/ring gear carrier
 W03_30-0019-09
No. Test values
Flywheel bolt shank length max. 61 mm
Vehicle with flywheel Ø443
: 392,435...392,575 mm
B Flywheel diameter for supporting the starter ring gear
Vehicle with flywheel Ø487
: 432,49...432,645 mm
C Flywheel diameter on the crankshaft flange 114,96...115,02 mm
Vehicle with flywheel Ø443
: 435...435,063 mm
D Flywheel diameter for supporting the clutch
Vehicle with flywheel Ø487
: 475...475,063 mm
Vehicle with flywheel Ø443
: 410 mm
Bolt-hole circle diameter for clutch
Vehicle with flywheel Ø487
: 450
Surface roughness (Rz) of clutch friction contact surface 16 µm
F Flywheel - total width 64 mm
Flywheel - minimum width between friction contact surface
E
and support flange in case of repair 55 mm
Flywheel - permissible radial and lateral run-out 0,05 mm
Starter ring gear
Test values
Vehicle with flywheel Ø443
: 392...392,14 mm
Starter ring gear - inner diameter
Vehicle with flywheel Ø487
: 432...432,155 mm
 Vehicle with flywheel Ø443
: 0,295...0,575 mm
Starter ring gear/flywheel overlap
Vehicle with flywheel Ø487
: 0,575...0,385 mm
Starter ring gear/flywheel - permissible radial run-out 0,5 mm
Starter ring gear - width 15,6...16 mm
Starter ring gear - rising temperature 250...280 °C
Vibration damper
Test values
Shank length of the bolt (M14x1.5) max. 60 mm
Shank length of the bolt (M16x1.5) max. 60,8 mm
Piston projection

N03_10-2016-01
No. Test values
Piston projection for cylinder crankcase mating surface (Piston
A
at TDC ) 0,28...0,5 mm
Pistons
Test values
Group designation BA :
101,781...101,79 mm
Piston diameter
Group designation BC :
101,79...101,799 mm
Standard: 102 BA :
64,36...64,4 mm
Measurement 1: 102 BC :
64,36...64,4 mm
Measurement 2: 102 BA 0.3
: 64,06...64,1 mm
Piston compression height Measurement 3: 102 BC 0.3
: 64,06...64,1 mm
Measurement 3: 102 BA 0.6
: 63,76...63,8 mm
Measurement 3: 102 BC 0.6
: 63,76...63,8 mm
Measurement 3: 102 BA 0.9
 : 63,46...63,5 mm
Measurement 3: 102 BC 0.9
: 63,46...63,5 mm
Piston rings
Test values
Groove 1, keystone ring :
max. 1 mm
Groove 2, taper face ring
with internal angle : max. 1
Piston ring end clearance
mm
Groove 3, bevelled ring
with spiral-type expander :
max. 1 mm
Piston ring folding-out value max. 43 mm
Connecting rod bolt

P03_10-0225-01
No. Test values
L Connecting rod bolt shank length max. 57 mm
Connecting rod
Test values
Standard : 70,054...70,093
mm
Measurement 0.1 :
69,954...69,993 mm
Measurement 0.25 :
Connecting rod bearing inner diameter for inserted connecting rod 69,804...69,843 mm
bearing shells Measurement 0.5 :
69,554...69,593 mm
Measurement 0.75 :
69,304...69,343 mm
Measurement 1.0 :
69,054...69,093 mm
Basic bore diameter for connecting rod bearing 75...75,019 mm
radial : 0,039...0,098 mm
Connecting rod bearing play
axial : 0,17...0,47 mm
Permissible deviation in axis parallelism between connecting rod
bearing bore and connecting rod bushing bore to a length of 50 mm max. 0,025 mm
Connecting rod bearing :
max. 0,008 mm
Permissible out-of-roundness of basic bores
Connecting rod bushing :
max. 0,006 mm
Connecting rod bushing inner diameter 42,03...42,04 mm
Connecting rod bushing in the connecting rod overlap 0,045...0,1 mm
Distance from connecting rod bearing seating to connecting rod
bushing inner diameter 156,51...156,445 mm
Crankshaft bolts
Test values
Shank length of the crankshaft bearing cap bolt max. 116 mm
Crankshaft
Test values
Axial play of the crankshaft 0,17...0,38 mm
Standard : 85,99...86,01 mm
Measurement -0.1 :
85,89...85,91 mm
Measurement -0.25 :
85,74...85,76 mm
Main bearing journal diameter Measurement -0.5 :
85,49...85,51 mm
Measurement -0.75 :
85,24...85,26 mm
Measurement -1.0 :
84,99...85,01 mm
Standard : 31...31,062 mm
Measurement -0.3 :
Thrust bearing journal width 31,3...31,362 mm
Measurement -0.5 :
31,5...31,562 mm
Main bearing journal width 31...31,2 mm
Standard : 69,995...70,015
mm
Measurement -0.1 :
69,895...69,915 mm
Measurement -0.25 :
Connecting rod bearing journal diameter
69,745...69,765 mm
Measurement -0.5 :
69,495...69,515 mm
Measurement -0.75 :
69,245...69,265 mm
 Measurement -1.0 :
68,995...69,015 mm
Connecting rod bearing journal width 34...34,2 mm
Main and connecting rod bearing journal permissible deviation of Limit value : max. 0,005
out-of-roundness mm
Main bearing journal : max.
0,005 mm
Permissible conicity
Connecting rod bearing
journal : max. 0,005 mm
Permissible lateral run-out max. 0,015 mm
Concentricity deviation measured at the centre main bearing journal
(supported at outer main bearing journal) max. 0,15 mm
Main bearing journal :
2,5...3 mm
Transition radii
Connecting rod bearing
journal : 2,5...3 mm
Hardness of main bearing and connecting rod bearing journals
(Rockwell hardness) min 52 HRC
Standard : 86,066...86,108
mm
Measurement 0.1 :
85,966...86,008 mm
Measurement 0.25 :
85,816...85,858 mm
Main bearing inner diameter
Measurement 0.5 :
85,566...85,608 mm
Measurement 0.75 :
85,316...85,358 mm
Measurement 1.0 :
85,066...85,108 mm
Permissible imbalance of crankshaft (with pin for flywheel fixing,
but without flywheel), recorded for main bearings two and six. max. 30 gcm
05 Control system
Camshaft
Test values
Axial play of the camshaft 0,3...0,7 mm
Hardness of cams and bearing journals 57...63 HRC
Camshaft gear seat : max.
0,02 mm
Camshaft concentricity deviation when mounted on the outer Cam base circle : max.
bearing journals 0,025 mm
All bearing points : max.
0,03 mm
 Inlet : max. 7,3 mm
Cam lifting of valve cam beyond the basic circle diameter
Exhaust : max. 8,2 mm
Cam lifting of unit pump beyond the basic circle diameter max. 13,8 mm
Valve tappets
Test values
Valve tappet outer diameter 17,944...17,965 mm
Valve tappet bore in the cylinder crankcase 18...18,018 mm
Valve timing
Test values
Inlet valve opens before TDC (at specified valve play) 17 Grad
Inlet valve closes after BDC (at specified valve play) 17 Grad
Exhaust valve opens before BDC (at specified valve play) 59 Grad
Exhaust valve closes after TDC (at specified valve play) 14 Grad
Valves

W05_30-0064-06
No. Test values
Inlet : max. 9,7 mm
Valve stroke at specified valve play
Exhaust : max. 10,7 mm
Shortfall of valve to cylinder-head mating surface 1,1...1,5 mm
Inlet : 20°
A Valve seat angle
Exhaust : 45°
 Inlet : 33,9...34,1 mm
B Valve disc diameter
Exhaust : 37,9...38,1 mm
Inlet : min 3,19 mm
F Width of valve seat on valve disc
Exhaust : min 3,35 mm
Inlet : 125,65...126,95 mm
C Valve length
Exhaust : 152,5...152,9 mm
Inlet : 7,935...7,95 mm
E Valve stem diameter
Exhaust : 7,925...7,94 mm
Inlet valve seat face machining dimension based on valve seat Dimension G : 31 mm
H
face diameter (G) Dimension H : 2,7...3,1 mm
Exhaust valve seat face machining dimension based on valve Dimension G : 36 mm
H
seat face diameter (G) Dimension H : 2,5...3,2 mm
Inlet : 0,03 mm
Rotating valve seat to valve stem
Exhaust : 0,03 mm
Permissible difference for the inlet valves, measured between
the cylinder head and the end of the valve stem max. 0,2 mm
Inlet : 54...60 HRC
Hardness at end of valve stem
Exhaust : 54...60 HRC
Valve guides

W05_30-0003-06
No. Test values
Standard : 14,028...14,046
A1 Outer diameter mm
Measurement 0.2 :
 14,228...14,246 mm
Measurement 0.5 :
14,528...14,546 mm
Standard : 14...14,018 mm
Measurement 0.2 :
A Bore diameter in cylinder head 14,2...14,218 mm
Measurement 0.5 :
14,5...14,518 mm
B Inner diameter (machining dimension) 8...8,022 mm
C Length 59,7...60,3 mm
Protrusion of the valve guide from the support plate to the Inlet : 13,7...14,5 mm
D
upper edge of the valve guide Inlet : 17,2...18 mm
Cover in the cylinder head 0,01...0,046 mm
Inner diameter (machining dimension) 8...8,022 mm
Inlet : 0,05...0,087 mm
Valve stem play
Exhaust : 0,06...0,097 mm
Valve seat rings

W05_30-0005-06
No. Test values
Standard : 35,07...35,08 mm
Measurement 0.3 :
A Inlet valve seat rings, outer diameter 35,37...35,38 mm
Measurement 0.5 :
35,57...35,58 mm
 Standard : 40,07...40,08 mm
Measurement 0.3 :
A Exhaust valve seat rings, outer diameter 40,37...40,38 mm
Measurement 0.5 :
40,57...40,58 mm
Inlet : 7,6...7,7 mm
E Height of valve seat rings
Exhaust : 8...8,1 mm
Inlet : 0,045...0,08 mm
Valve seat rings cover in cylinder head
Exhaust : 0,045...0,08 mm
Distance between mating surface cylinder head and face of Inlet : 3,7...4 mm
D
valve seat ring Exhaust : 3,3...3,6 mm
Standard : 35...35,025 mm
Measurement 0.3 :
B Bore diameter for inlet valve seat rings in cylinder head 35,3...35,325 mm
Measurement 0.5 :
35,5...35,525 mm
Standard : 40...40,025 mm
Measurement 0.3 :
B Bore diameter for exhaust valve seat rings in cylinder head 40,3...40,325 mm
Measurement 0.5 :
40,5...40,525 mm
Inlet : 11,4...11,6 mm
C Bore depth of the valve seat ring in the cylinder head (C)
Exhaust : 11,4...11,6 mm
Inlet : 1,5...2,5 mm
Valve seat width on valve seat ring
Exhaust : 1,8...3 mm
07 Mixture control
General basic
model
Test values
OM 502 : 2 Impulse/Kw
OM 501 : 3 Impulse/Kw
OM 457 : 3 Impulse/Kw
Number of pulses per revolution of the crankshaft
OM 906 : 3 Impulse/Kw
OM 904 : 2 Impulse/Kw
M 447 : 3 Impulse/Kw
OM 906 LA (Euro
3)
Low pressure fuel system
Test values
Engine idling speed : min
Fuel pressure after fuel filter 4,3 bar
Limiting speed : 4...6,5 bar
Quantity of fuel returned to the nozzle holder assemblies (Test time: Engine idling speed:
5 mins ) covered with oil
 Limiting speed: only drops
at the most
Idling speed and limiting
Quantity of fuel returned to the fuel filter housing output
speed : max. 0,3 l/min
Engine idling speed :
0,9...1,7 l/min
Quantity of fuel returned to the overflow valve
Limiting speed : 2,7...7,5
l/min
Engine idling speed : -
0,09...-0,12 bar
Fuel intake pressure
Limiting speed : -0,4...-0,5
bar
Low pressure fuel circuit tightness (Test pressure 10 bar, test time: 5
mins) max. 0,25 bar
13 Air compressor/belt drives
Belt tensioner
Test values
Minimum distance to the stop 5 mm
14 Exhaust cleaning system, exhaust manifold
Exhaust manifold
Test values
Exhaust manifold bolt shank length max. 47,5 mm
18 Lubrication
Engine oil circuit
Test values
Engine idling speed : min
0,5 bar
Engine oil pressure
Maximum engine speed :
min 2,5 bar
20 Cooling
Test values
Coolant thermostat opening point 83±2 °C
95 °C
Coolant thermostat fully open
Stroke : min 8 mm
Coolant thermostat short-circuit valve closed at 92 °C
Coolant pump
 W20_10-0016-06
No. Test values
Gap between vane wheel and coolant pump housing (A) 0,6...1 mm
Distance between coolant pump housing and flange (B) 112,7...113,3 mm
Protrusion of the vane wheel in relation to the coolant pump
housing (C) max. 0,5 mm
42 Brake chassis/component
Brake pad

M42_10-0020-02
No. Test values
 C = Thickness of new brake pad (friction material and brake
C
pad backplate) 30 mm
D D = Thickness of the brake pad backplate 9 mm
E E = Wear limit of the friction material 2 mm
F = Wear limit of the brake pad (friction material and brake
F
pad backplate) 11 mm
Permissible difference in wear between the brake pads on one
brake max. 5 mm
Permissible difference in wear between the brakes on one axle max. 6 mm
Thickness and wear of the brake disc

W42.10-0008-02
No. Test values
A A = Thickness of new brake disc 45 mm
B B = Wear limit of the brake disc 37 mm
B B = Repair limit of the brake disc 39 mm
C C = Permissible wear of the brake disc on each side max. 4 mm
Surface conditions of the brake disc
 W42.10-0009-02
No. Test values
a = Permissible length of the cracks running in a radial
a
direction max. 60 mm
b = Permissible depth and width of the cracks running in a
b
radial direction max. 1,5 mm
b b = Permissible depth of grooves in the disc surface max. 1,5 mm
Brake calliper check values
Test values
Clearance 0,5...1,1 mm
Permissible floating bearing guide sleeve bearing play max. 3 mm
Brake calliper movement range A min 30 mm
Torque for pulling in the guide sleeve 8...45 Nm
Permissible torque when pulling in the boot max. 8 Nm
Permissible depth of grooves in the brake pad bearing faces max. 0,5 mm
Permissible travel of the threaded tubes during inspection and repair
work max. 30 mm
Protrusion of diaphragm cylinder/combination cylinder seal

M42_10-0123-71
No. Test values
A Protrusion of diaphragm cylinder/combination cylinder seal min 3 mm
46 Steering
Steering mechanical system
Test values
Permissible axial play of the track rod pivots max. 2 mm
Permissible steering play on steering wheel circumference
(measured on the circumference of the steering wheel with engine
running and in the straight-ahead position) max. 40 mm
83 Heating, ventilation, air-conditioning (HLK)
Bock FK 30
refrigerant
compressor
Test values
Final vacuum on evacuation max. 1 mbar
Bock FK 40
Refrigeration
compressor
Test values
Final vacuum on evacuation max. 1 mbar