Service manual Diesel engine, Splitter box

Diesel engine

4.1.4 Coolant temperature sensor – B708

Fuel temperature sensor – B709
The coolant temperature sensor B708 is attached to the thermostat housing of
the engine, while the fuel temperature sensor B709 is fitted in the fuel supply
line. Both have the task of signalling the temperature to the engine control unit
(ECU) in the form of an electrical resistance. The ECU uses this signal for:
Coolant temperature:
– Indicating the coolant temperature in the cab
– Controlling the fan drive
– Preglow control
– Engine power limiting control
Coolant temperature [°C] -100 -15 100 101 120 150
Power reduction [%] 10 0 0 4 50 50
– Controlling the engine to increase the idling speed
Coolant temperature [°C] -100 -90 -40 -10 20
Idling speed increase [rpm] 0 200 200 100 0

Fuel temperature:
– Controlling the fan drive
– Engine power limiting control

Fuel temperature [°C] -100 -5 0 75 80 85 100

Power reduction
10 3 0 0 3 10 30
[%]

Design
The temperature sensor is a resistance thermometer which operates with an
NTC characteristic (semiconductor).

Function description
Basic function
The resistance in the sensor decreases as the temperature rises. The curve is not
a straight line. If the sensor is defective, a temperature of -100 °C is assumed.

Coolant resistance characteristic B708

Coolant and fuel
105
temperature sensor 100
95
90
85
LBH/Version 01/10.2006/en/nk/29.01.2007

80
75
Temperature (°C)

70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60

Resistance (kOhm )

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Diesel engine, Splitter box Service manual
Diesel engine

4.1.5 Charge air temperature sensor – B707

The charge air temperature sensor B707 is attached to the air intake pipe of
the engine and has the task of signalling the charge air temperature to the
engine control unit (ECU) in the form of an electrical resistance. The ECU
uses this signal for:
– Controlling the fan drive
– Preglow control
– Engine power limiting control
Charge air
-100 -15 75 80 85 100
temperature [°C]
Power reduction [%] 10 0 0 0 10 30

Design
The temperature sensor is a resistance thermometer which operates with an
NTC characteristic (semiconductor).

Function description

Basic function
The resistance in the sensor decreases as the temperature rises. The curve is not
Charge air temperature sensor a straight line. If the sensor is defective, a temperature of 100 °C is assumed.

Charge air resistance characteristic B707

105
100
95
90
85
80
75
Temperature (°C)

70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Resistance (kOhm ) LBH/Version 01/10.2006/en/nk/29.01.2007

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 Service manual Diesel engine, Splitter box
Diesel engine

4.1.6 Charge air pressure sensor – B703

The charge air pressure sensor B703 is attached to the air intake pipe of the
engine and has the task of signalling the charge air pressure to the engine control
unit (ECU) in the form of an electrical voltage. The ECU uses this signal for:
– Engine power limiting control
Power reduction (%) Speed (rpm)

1000 1300 1600 1900 2100

Atmospheric 550 23.1 24.1 24.4 24.4 23.3

pressure 4850*
(mbar)
Height above sea 620 19.5 19.6 19.1 19.1 18.0
level* 3950*
(m)
690 14.2 14.8 13.9 13.6 12.6
3100*

770 10.0 10.1 8.9 8.4 7.2

2250*

840 0.0 0.0 0.0

1550*

Design
The charge air pressure sensor is an absolute pressure sensor with a
membrane and an evaluation circuit. At atmospheric pressure, an absolute
pressure sensor is subject to approximately 1 bar (at sea level 1030 mbar).
1 Electrical connections
2 Evaluation circuit
3 Membrane with sensor element
4 Pressure port
5 Fixing thread

Function description

Basic function
Cross section of speed sensor The electrical resistance varies on the layers applied to the membrane as
they change shape. This deformation due to the accumulating system
pressure alters the electrical resistance and causes a change in the voltage
of the resistance bridge, which has a 5 V supply.
This voltage is in the range of 0 to 70 mV (depending on the pressure) and is
amplified in the evaluation circuit to between 0.5 and 4.5 V.
LBH/Version 01/10.2006/en/nk/29.01.2007

Attention
Never measure resistance on a pressure sensor.
! Malfunctions are indicated by service codes in display.

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Diesel engine, Splitter box Service manual
Diesel engine

4.1.7 Oil pressure sensor – B701

The oil pressure sensor B701 is attached to the crankcase of the engine and
has the task of signalling the oil pressure to the engine control unit (ECU) in
the form of an electrical voltage. The ECU uses this signal for:
– Indication in the cab
– Controlling the engine as a function of the safety curve:
300 1000 1400 1800 2100

Design
The oil pressure sensor is a relative pressure sensor with a membrane and
an evaluation circuit. At atmospheric pressure, a relative pressure sensor is
subject to 0 bar.
1 Electrical connections
2 Evaluation circuit
3 Membrane with sensor element
4 Pressure port
5 Fixing thread

Function description

Basic function
Cross section of speed sensor
The electrical resistance varies on the layers applied to the membrane as
they change shape. This deformation due to the accumulating system
pressure alters the electrical resistance and causes a change in the voltage
of the resistance bridge, which has a 5 V supply.
This voltage is in the range of 0 to 70 mV (depending on the pressure) and is
amplified in the evaluation circuit to between 0.5 and 4.5 V.

Attention
Never measure resistance on a pressure sensor.
! Malfunctions are indicated by service codes in display.
LBH/Version 01/10.2006/en/nk/29.01.2007

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Fuel system

4.2 Fuel system

Technical data
See section 2.1

Design
The fuel tank is located behind the right cab access.
LBH/Version 01/10.2006/en/nk/29.01.2007

Fuel system
1 Tank cap 5 Intake line 8 Fuel cooler
2 Filler strainer 6 Return line 9 Drain valve
3 Fuel level sensor 7 Diesel engine 10 Fuel tank
4 Distributor port

Function description
The fuel is drawn up by the fuel pump via the intake line and fuel pre-filter (water
and dirt separator) and is delivered to the injection elements via a fine filter.

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Diesel engine, Splitter box Service manual
Fuel system

4.2.1 Fuel level sensor

Design
The fuel level sensor is fitted vertically in the tank.
It is connected via a lead and plugs to the display unit.
The sensor tube contains two electrodes to transmit the fuel level in the tank.

Function description
The fuel level sensor tube 2 contains electrodes 3 which measure the fuel
level using a capacitive resistor.
The electronics in the head of the fuel level sensor 1 transmit a corresponding
voltage signal of 1 V – 4 V to input module 1 – A16a pin 23.
Input module 1 converts the signal to a digital signal and forwards it via the
master electronics to the fuel level display in the display unit A13.
The fuel level sensor is earthed via input module 1 – pin 65.

Fuel level display

The lower the fuel level the higher the voltage and thus the level shown on
the fuel level display.
The “reserve” fuel level is shown by the fuel level symbol field flashing.

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 Service manual Diesel engine, Splitter box
Fuel system

4.2.2 Fuel pre-filter

The fuel pre-filter protects the engine's fuel system (pump, pump elements,
injection valves, valves and pistons) from dirt and water penetration.

Design
The fuel pre-filter acts as both a water separator and a filter. It is fitted in the
fuel intake line between the engine control unit and the fuel pump.
The intake line is connected via the engine control unit (cooler) to the fuel
tank. The outlet line is connected to the fuel pump.
The water probe in the water collector monitors the condensate in the fuel
pre-filter; if the water level is too high, it generates a service code via the
engine control unit to the display unit.

Fuel pre-filter
1 Hand pump 4 Water collector
2 Filter head 5 Drain cock
3 Filter cartridge 6 Water sensor
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Diesel engine, Splitter box Service manual
Fuel system

4.2.3 Fuel fine filter

Technical data
See section 2.1
The filter can be serviced without any tools. The filter can be removed and
replaced by hand during a service.

Design
The fuel filter is a fine filter with a water drain valve and is fitted between the
fuel pump and the injection pump.
It has a disposable filter cartridge which must be replaced each time it
is serviced.

Fuel fine filter

1 Filter head 2 Filter cartridge

Function description
The fuel fine filter protects the fuel system from contamination.
The diesel fuel is pumped under pressure from the fuel pump through the
filter intake into the filter insert.
The pressure of the fuel pump forces the fuel through the filter membrane.
LBH/Version 01/10.2006/en/nk/29.01.2007

The filtered fuel then flows through the outlet in the filter head via the fuel
line to the injection pump.
The water in the fuel system is separated by the impregnation of the filter
insert, and then settles in the filter at the bottom.
The filter can be emptied during maintenance by opening the drain valve.

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 Service manual Diesel engine, Splitter box
Fuel system

4.2.4 Refuelling pump (optional)

Technical data
See section 2.1
The refuelling pump is mounted on the right of the rear section.
The refuelling pump is only suitable for diesel fuel.
The refuelling system is designed to assist filling the diesel fuel from the
container to the fuel tank.

Design

Main components of the refuelling pump

1 Intake connection 4 DC motor
2 Pressure port 5 Electrical connection
3 Supply pump
LBH/Version 01/10.2006/en/nk/29.01.2007

Components of the refuelling pump

1 Snap ring 5 Seal 9 Electrical connection
2 Check valve 6 Discharge housing 10 Carbon brush
3 Intake housing 7 Feather key
4 Impeller 8 DC motor

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Fuel system

Function description

Refuelling system

Refuelling pump
The refuelling pump 5 is a rotary vane pump which draws in fuel via the
intake line 6 and the intake line extension 7 with suction strainer 8, from the
container 9 and pumps it through the discharge line 4 to the fuel tank 3 of
the machine.
The refuelling pump 5 can be switched on and off using the removable key 2.
The refuelling pump 5 is filled with fuel via the discharge line before it is first
used. This means it is self-priming. The diesel fuel also lubricates the
mechanical seals in the pump.
A check valve in the intake port prevents the refuelling pump 5 from running
empty. This means the pump remains self-priming.
The DC motor does not have internal thermal protection; it is designed to run
for a maximum of 15 minutes.
The external 20 amp fuse F05 (fitted in the instrument panel) protects the
pump from short-circuits and overload.

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 Service manual Diesel engine, Splitter box
Air filter system

4.3 Air filter system

Design

Air filter system

1 Rain cap 4 Vacuum switch
2 Fixing clips 5 Filtered air intake manifold
3 Air filter 6 Fixing clips

Function description
The engine takes in fresh air via the rain cap 3 and the air filter 5. The
filtered air is provided to the engine via the turbocharger.

4.3.1 Air filter

Design
LBH/Version 01/10.2006/en/nk/29.01.2007

Air filter
1 Secondary element 4 Fixing clips
2 Primary element 5 Dust extraction valve
3 Service cap 6 Air filter housing

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