Workshop 2011 - 03121936
Workshop 2011 - 03121936
0312 1936 en
Workshop Manual
2011
0312 1936 en
Illustrations and data in this workshop manual are subject to technical change in the course of improvements to the engines. Reprinting and reproductions of any kind, even in part, require our written permission.
Deutz AG Service Information Systems Deutz-Mlheimer Strasse 147-149 D - 51063 Kln Tel.: + 49 (0) 221-8 22-0 Fax: + 49 (0) 221-8 22-53 58 http://www.deutz.de Printed in Germany All rights reserved 1st edition, 11/2004 Order No. 0312 1936
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Contents 2011
Foreword
General
User notes
3.1 3.2 3.2.1 3.2.2 3.3 3.4 3.5 General Specifications Safety regulations and rules for the prevention of accidents Disposal regulations Operating manual and workshop manual Job cards Explanation of symbols
Technical data
4.1 4.2 Test and adjustment data Tightening specifications
Job cards
Commercial tools
Special tools
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Contents 2011
Notes
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2011
Foreword
1
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1 Foreword 2011
Notes
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1 Foreword 2011
Read and observe the information in this documentation. You will avoid accidents, retain the manufacturers warranty and have a fully functional, ready to use engine at your disposal. This engine is built exclusively for the purpose according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user will bear the sole risk in this case. Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with it and instructed in the dangers. Make sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents. Failure to observe this documentation can lead to malfunctions and engine damage as well as injury to persons for which the manufacturer will accept no liability. Prerequisite for the proper maintenance and repair is the availability of all necessary equipment, commercial tools and special tools as well as their perfect working order. Engine parts such as springs, clamps, elastic retaining rings etc. constitute an increased risk of injury when not used properly. The pertinent rules for the prevention of accidents and other generally recognized safety and industrial medicine rules must be observed. Maximum cost effectiveness, reliability and long life is only guaranteed when DEUTZ original parts are used. Repair of the engine must comply with use for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorized modification to the engine exclude manufacturer liability for resulting damages. Failure to observe this will lead to voiding of the warranty! The engines made by DEUTZ are developed for a wide range of applications. A wide range of variants ensures that the respective special requirements are met. The engine is equipped according to the installation, i.e. not all the parts and components described in this documentation are installed in your engine. We have done our best to clearly identify the differences so that you can easily find the operating, maintenance and repair instructions relevant to your engine. We are at your service for any questions you may have in this matter. Your DEUTZ AG
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1 Foreword 2011
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2011
General
2
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2 General 2011
Notes
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2 General 2011
DEUTZ engines are the product of years of research and development. The profound know-how gained in connection with high quality requirements is the guarantee for manufacturing of engines with a long life, high reliability and low fuel consumption. Naturally the high requirements for protection of the environment are also met.
Maintenance and care are decisive for whether the engine satisfactorily meets the set demands. Compliance with the prescribed maintenance times and the careful execution of maintenance and care are therefore essential. Difficult operating conditions deviation from normal operation must be observed especially.
DEUTZ AG Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast, professional repairs using original parts in the event of damage. Original parts of the DEUTZ AG are always produced according to the latest state of the art. Information about our service can be found at the end of this documentation.
Take care when the engine is running Only perform maintenance work or repairs when the engine is at a standstill. Replace any removed protective devices upon completion of the work. When working on the running engine, work clothing must be close fitting.
Safety
!
This symbol accompanies all safety notes. Observe these carefully. Also pass on the safety instructions to your operating personnel. The General safety regulations and rules for the prevention of accidents of the legislator must be observed additionally.
Note
This symbol accompanies information of a general kind. Observe these carefully.
Asbestos
Gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair work.
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2 General 2011
Notes
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2011
User notes
3
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Caution!
!
The rules for the prevention of accidents and the safety regulations must be observed during maintenance work.
Also observe the special safety regulations for the different maintenance groups which are listed in detail as job cards in the Job cards chapter (cf. also section 1.2). See the maintenance schedules for the maintenance intervals. These also inform you of the work to be performed. The job cards provide technical instructions for performing the work.
3.2
3.2.1
Specifications
Safety regulations and rules for the prevention of accidents
For various maintenance groups, detailed safety notes in the form of job cards have been compiled, these precede the job cards of the respective maintenance groups. The legally prescribed rules for the prevention of accidents (available from professional associations or from dealers) must be observed. These are dependent on the installation site, operating mode and the operating and auxiliary materials being used. Special protection measures depending on the respective work are specified and identified in the job description. It generally applies among other things: for the personnel - Only instructed personnel may operate or maintain the engine. Unauthorized persons may not enter the engine room. - Wear close fitting clothing and ear protectors in the engine room when the engine is running. - Only appoint qualified personnel to do repairs and maintenance. for the engine room: Ensure adequate ventilation (do not cover air shafts) Install first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly. Only store inflammable materials in the engine room if these are necessary for operating the system. Smoking and naked lights are prohibited in the engine room.
For operation and maintenance of the engine: - Only start the engine when all protection devices are installed. Make sure that no-one is standing in the danger area. - Only perform cleaning, maintenance and repair work when the engine has been shut down and secured against starting.
!
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3.3
To structure the information to suit the user, the service documentation is divided into operating manual and workshop manual. The operating manual contains a general description and instructions for all other maintenance work. It contains the following chapters: 1. General, Contents 2. Engine description 3. Operation 4. Operating materials 5. Maintenance 6. Care and maintenance work 7. Faults, causes and remedies 8. Engine corrosion protection 9. Technical data 10. Service The workshop manual assumes knowledge of the contents of the operating manual, this applies especially for the safety regulations. Minor repairs and emergency measures on components are described the execution of which requires more effort and appropriately qualified personnel.
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Dokumentationsart Der fhrende Buchstabe steht fr die Art der Dokumentation. W = Werkstatthandbuch I = Instandsetzungsanleitung
Instandhaltungsgruppe (fr alle Motoren gleich) 00 01 02 03 04 05 06 Allgemein / bergreifende Ttigkeiten Zylinderkopf Triebwerk Kurbelgehuse Motorsteuerung Drehzahlregelung Abgasanlage / Aufladung 07 08 09 10 11 12 13 Kraftstoffsystem Schmierlsystem Khlflssigkeitssystem Druckluftsystem berwachungssystem Sonstige Bauteile Elektrische Anlage
Teilsystem (Bauteil) Die Teilsysteme unterscheiden sich je Instandhaltungsgruppe. Allgemein gltig: 00 Teilsysteme-bergreifend bzw. Sicherheitsvorschriften (SV) 01 Systemparameter bzw. generelle Kontrollen
Fortlaufende Nummer Zhlend je Teilsystem (Bauteil) Verschiedene Ttigkeiten je Teilsystem (Bauteil) Versions-Unterschiede
W 03-03-03
80301 3
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Kurbelgehuse W 00-00-00
13 12 11 6 5
3
10 6
8
39744 1
1. DEUTZ, publisher of the service documentation 2. Engine type (e. g. 914) 3. Maintenance group 4. Job card number 5. Reference to other job cards, Specifications and similar 6. Explanatory graphics 7. Page number
8. DEUTZ-internal part number of job card and technical order number 9. Date of issue of the job card 10. Work sequence 11. Safety and general notes 12. Necessary tools, auxiliary materials and spare parts 13. Title of the job card
Note
For inquiries about the job card please always state the engine type (2), the job card number (4), the page number (7), the date of issue (9) or alternatively the DEUTZ-internal part number (8).
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Auxiliary material
For example: Lifting gear, adhesive
Tools
for example:100 400 - meter
3
Note
For example: Cylinder head is dismantled.
References
For example: Job card no. W xx-yy-zz
01 61
01001
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2011
4
4.1
Technical data
Test and adjustment data
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4 Technical data
4.1 Test and adjustment data Notes
2011
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Engine general
Name Engine weight according to DIN 70020-A Remark F2L engine F3L engine F4L engine F2M engine F3M engine F4M engine BF3L engine BF4L engine BF3M engine BF4M engine Value 175 217 256 169 210 kg 248 222 257 215 250 four-stroke diesel Direct injection Diameter 94 112 FL/M engines BFL/M engines 19:1 17.5:1 left 25 to 30 22 to 27 180 120 bar bar mm mm Unit
00 10 00 20 00 31 00 32 00 40
00 50
Direction of rotation
00 51
Compression pressure
00 70
Ignition distance
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4 Technical data
4.1 Test and adjustment data
ID No. 00 71 Name Ignition sequence Remark 2-cylinder 3-cylinder 4-cylinder 00 81 Cylinder arrangement 2-cylinder A = Manifold side B = Operating side
2011
Value 1-2 1-2-3 1-3-4-2 Unit
A
1 2
4
Cylinder arrangement 3-cylinder A = Manifold side B = Operating side
B A
1 2 3
39617 0
B
Cylinder arrangement 4-cylinder A = Manifold side B = Operating side
39618 0
A
1 2 3 4
B
01 00
ID No. 01 01 01 02 01 03 01 04
39619 0
Cylinder head
Name Bore diameter for valve seat ring (inlet) Bore diameter for valve seat ring (outlet) Bore diameter for valve seat ring (inlet) Bore diameter for valve seat ring (outlet) Additional information Standard Standard 1. Overmeasure step 1. Overmeasure step Value 42.590 - 42.615 36.010 - 36.015 42.800 - 42.825 37.200 - 37.225 Unit mm mm mm mm
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12.000 - 12.018
mm
01 08 01 09 01 10 01 12
Height of cylinder head Height of cylinder head Valve guide External diameter of the valve guide
mm mm
12.025 - 12.035
mm
01 16
mm
01 17
Internal diameter of valve guide (outlet) Repair Fit E7 Valve seat ring External diameter of the valve seat ring (inlet) External diameter of the valve seat ring (outlet) External diameter of the valve seat ring (inlet) External diameter of the valve seat ring (outlet) External diameter of the valve seat ring (inlet) External diameter of the valve seat ring (outlet) Valve Valve shaft diameter (inlet) Standard Standard
mm
01 20 01 21
42.680 0.006
mm
01 22
Standard
37.075 0.006
mm
01 23
Repair standard
42.67 0.005
mm
01 24
Repair standard
37.07 0.005
mm
01 27
1. Overmeasure step
42.87 0.005
mm
01 28
1. Overmeasure step
37.27 0.005
mm
01 30 01 31
7.98
-0.015
mm
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4 Technical data
4.1 Test and adjustment data
ID No. 01 32 Name Valve shaft diameter (outlet) Additional information
2011
Value Unit
Standard Wear limit Wear limit Wear limit FL/M engines Wear limit BFL/M engines
-0.015
mm mm mm mm
01 33 01 34 01 35
Valve shaft clearance (inlet) Valve shaft clearance (outlet) Valve edge strength on valve head (inlet)
1.4
mm
01 36
1.2
mm
mm mm mm
01 37 01 38 01 40 01 41
Valve head diameter (inlet) Valve head diameter (outlet) Valve seat Valve seat width on valve seat ring (inlet) FL/M engines B/FL/M engines
mm mm mm mm mm
01 42
01 45
1.3
mm
01 46
1.53
mm
1.3
mm
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01 48
01 50 01 51
Valve spring Valve spring length (unclamped normal) Wire diameter 3.35 mm Wire diameter 3.40 mm 38.9 39.3 mm mm
01 60 01 61
Valve clearance Valve clearance (inlet) after a cooling time of at least 0.5 h (oil temperature < 80 C) Test and setting values in inspections from a running time of 50 operating hours of the engine or life of the cylinder head gasket (see maintenance schedule) Setting values when changing the cylinder head gasket
0.3 0.05
mm (0.4 0.05)
01 62
after a cooling time of at least 0.5 h (oil temperature < 80 C) Test and setting values in inspections from a running time of 50 operating hours of the engine or life of the cylinder head gasket (see maintenance schedule) Setting values when changing the cylinder head gasket
0.5 0.05
mm (0.6 0.05)
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4 Technical data
4.1 Test and adjustment data
ID No. 01 63 Name Valve clearance setting scheme Turn over engine up until reaching the valve overlap cyl. no. 1. Additional information
2011
Value Unit
Note
According to the order below (see table) the valve clearance setting is possible with 2 crankshaft revolutions 360. Crankshaft setting 1 Cyl. no. 1 = overlap
4
Crankshaft setting 2 Turn the crankshaft one rev on (360).
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01 73
mm mm Rz mm
01 74 01 93 01 98
02 00
ID No. 02 02 02 03 02 04
Drive system
Name Main bearing pin Diameter of the main bearing pin Undermeasure graduation for main bearing pin Standard 1. Stage 2. Stage 69.970 - 69.990 0.25 0.50 69.47 Wear limit Standard 0.008 58
+4
Additional information
Value
Unit
mm mm mm mm mm HRC
02 05
Limit value for undermeasure graduation of the main bearing pin Unroundness of the main bearing pin Surface hardness of the main bearing pin Fit bearing pin Width of fit bearing pin Undermeasure graduation for fit bearing pin Limit value for undermeasure graduation of the fit bearing pin (width) 9/22 1. Stage
02 06 02 07
02 10 02 11 02 12
35 +0.04 0.4
mm mm
02 13
35.44
mm
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4 Technical data
4.1 Test and adjustment data
ID No. 02 20 02 21 02 22 02 23 Lifting journal Width of lifting bearing journal Diameter of the lifting bearing journal Undermeasure step for lifting bearing journal Stroke 112 mm 1. Stage 2. Stage 02 24 Limit for undermeasure step of the lifting bearing journal Unroundness of the lifting bearing journal Concentricity of the crankshaft Hollow throat radius lifting and main bearing journal Wear limit max. deviation Do not damage hollow throat when reworking! Stroke 112 mm 31 +0.2 54.970 - 54.990 0.25 mm 0.50 54.47 mm mm mm Name Additional information
2011
Value Unit
02 25
0.01 0.05
+ 0.5
mm mm
02 26 02 27
1.9
mm
02 30 02 31
Crankshaft main bearing Internal diameter of the main bearing shells Undermeasure graduation for main bearing shells Standard 1. Stage 2. Stage 70.020 - 70.055 0.25 mm 0.50 0.100 - 0.273 0.4 2.4
+ 0.05
mm
02 32
02 34
mm mm mm
02 35
Standard
02 36
1. Overmeasure step
2.6
+ 0.05
mm
02 40 02 41
Con-rod Parallelism of the con rod to the piston bolt at a distance of 100 mm 0.03 mm
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0.03
mm
02 43
Internal diameter of the piston bolt bush Standard FL/M engines Standard BFL/M engines
02 45
Theoretical clearance between Piston bolt bush (con rod) and piston bolt Clearance between piston and piston bolt Con rod bearing Internal diameter of the con rod bearing shells (in installed state) Limit value for undermeasure graduation of the con rod bearing shells Undermeasure graduation of the con rod bearing Con rod bearing bore in con rod Theoretical clearance between the con rod bearing and the lifting journal Con rod bearing clearance Piston bolt Diameter of the piston bolt
Wear limit
0.08
mm
02 48
Wear limit
0.004 - 0.015
mm
02 50 02 52
55.024 - 55.055
mm
02 53
54.524 - 54.555
mm
02 54
mm mm mm mm
02 55 02 56
02 57 02 60 02 61
02 62
Piston bolt clearance between con rod and piston bolt Piston
02 70
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4 Technical data
4.1 Test and adjustment data
ID No. 02 71 Name Diameter of the piston Additional information Measuring point 1 at height 22 mm FL/M engines Measuring point 1 at height 25 mm BFL/M engines Measuring point 1 at height 25 mm BFL engines without cooling duct
2011
Value Unit
93.920
93.900
mm
93.880
02 72
Measuring point 2 at height 44.5 mm FL/M engines Measuring point 2 at height 47 mm BFL/M engines Measuring point 2 bat height 47 mm BFL engines without cooling duct
93.856
93.840
mm
93.820
02 73
Measuring point 3 at height 69.7 mm FL/M engines Measuring point 3 at height 66.5 mm BFL/M engines Measuring point 3 at height 66.5 mm BFL engines without cooling duct
93.670
93.720
mm
93.700
02 74 02 75 02 76 02 77
Overmeasure graduation Piston overlap for cylinder head gasket Piston overlap for cylinder head gasket Piston overlap for cylinder head gasket 1 Notch 2 Notches 3 Notches
mm mm mm mm
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20 79
Piston class A Stroke 112 mm only in FL/M engines Piston class B Stroke 112 mm only in FL/M engines
196.380 - 196.490
mm
196.491 - 196.690
mm
02 80 02 81
Piston rings Piston ring 1st ring Rectangular ring External diameter/ internal diameter x height FL/M engines External diameter/ internal diameter x height BF3/4L/M engines External diameter/ internal diameter x height External diameter/ internal diameter x height
4
94.0 x 2.0 x 3.9 mm
02 82
02 83
External diameter/ internal diameter x height External diameter/ internal diameter x height Double-sided trapezoidal ring Wear limit Rectangular ring Wear limit
02 84
Piston ring joint clearance of the 1st piston ring BFL/M engines Piston ring joint clearance of the 1st piston ring FL/M engines
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4 Technical data
4.1 Test and adjustment data
ID No. 02 85 Name Piston ring joint clearance of the 2nd piston ring B/FL/M engines Piston ring joint clearance of the 3rd piston ring Additional information minute ring Wear limit Roof chamfer ring Wear limit FL/M engines Oil slit ring B/FL/M engine 02 87 Axial clearance of the 1st piston ring Rectangular ring Axial clearance of the 1st piston ring Wear limit FL/M engines Wear limit BFL/M engines
2011
Value 1.5 - 2.0 mm 2.5 0.4 - 0.7 1.2 Unit
02 86
mm
0.3 - 0.6
0.2 Trapezoidal groove wear gauge contact with piston 0.2 0.15 1.975 - 1.990 mm 3.0 1.975 - 1.990 2.975 - 2.990 mm mm mm
02 88 02 89 02 91
Axial clearance of the 2nd piston ring Axial clearance of the 3rd piston ring Piston ring height 1st. piston ring
mm mm
02 92 02 93
Piston ring height 2nd piston ring Piston ring height 3rd piston ring
minute ring Roof chamfer ring Wear limit Oil slit ring Wear limit
2.975 - 2.990
02 95
Angle of twist to each other Angle of twist of spring joint to piston ring joint Piston class A Piston class B
90 - 120
02 96
Position of the piston ring joints roof chamfer ring Compression height
mm mm
20 97
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03 00
ID No. 03 10 03 11
Crankcase
Name Camshaft bearings Bore diameter for camshaft bearing liner in crankcase External diameter of the camshaft bearing liner Internal diameter of the camshaft bearing liner Camshaft bearing liner Bore for camshaft main bearing Diameter of the main bearing bore Standard Fit H6 75.000
+0.019
Additional information
Value
Unit
Fit H7
58
+0.030
mm
03 12
Standard
58.075
+0.045
mm
03 13
mm mm
03 14 03 20 03 21
mm
03 27 03 30 03 31
Fit bearing width on crankcase Cylinder Bore diameter of the cylinder Standard Wear limit Overmeasure step Wear limit of the overmeasure step
30 - 0.033
mm
+ 0.020
mm mm
03 32 03 41
+ 0.020
mm
03 42
94.6
mm
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4 Technical data
4.1 Test and adjustment data
04 00
ID No. 04 10
2011
Engine control
Name Control times for 1 mm valve clearance Inlet opens after UT Inlet closes after LT Outlet opens before LT Outlet closes before UT Camshaft Cam stroke (inlet) Cam stroke (outlet) Diameter of the camshaft bearing pin Standard 6.6 0.08 6.8 0.08 53.045 - 53.060 mm mm mm 312 1648 2748 412 Additional information Value Unit
04 11 04 12 04 13 04 14
04 20 04 21 04 22 04 31
05 00
ID No. 05 00 05 04 05 05 05 06 05 41
Speed governing
Name Speed governing Setting screw for full load stop Setting screw for minimum speed Screw in depth of the adapter capsule Full load stop (charge pressuredependent) in fuel filter console Stop screw 12 0.5 23 0.1 6.4 0.5 18 1 mm mm mm mm Additional information Value Unit
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Fuel system
Name Additional information Value Unit
Note
Only injection pumps with the same classification may be installed per engine. 07 11 Make/Type (Motorpal) PCIM9F2071 PCIM9F2073 Make/Type (Bosch) PF 30 V, see rating plate PF 30 V, see rating plate
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4 Technical data
4.1 Test and adjustment data
ID No. 07 16 07 17 Name Injection pump length "X" Standard roller tappet Motorpal TN 0428 1810 Injection pump length "X" Standard roller tappet Motorpal TN 0428 1814 Injection pump length "X" Hydro-roller tappet Motorpal TN 0428 6791 Injection pump length "X" Hydro-roller tappet Motorpal TN 0428 6450 Injection pump length "X" Standard roller tappet Motorpal TN 0428 6681 Injection pump length "X" Hydro-roller tappet Motorpal TN 0428 6792 Additional information Color marking: black Camshaft stroke 11.0 mm FL/M engine Color marking: green Camshaft stroke 11.0 mm BFL/M engine Color marking: blue Camshaft stroke 11.0 mm FL/M engine Color marking: red Camshaft stroke 11.0 mm BFL/M engine Color marking: green Camshaft stroke 11.7 mm BFL/M engine Color marking: red Camshaft stroke 11.7 mm BFL/M engine
2011
Value Unit
60.9
mm
60.9
mm
52.1
mm
52.1
mm
61.6
mm
52.8
mm
A B C D 11.0 11.7 mm mm
07 19
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4 Technical data
4.1 Test and adjustment data
ID No. 07 31 07 50 07 51 Name Beginning of pumping Injection valve Nozzle type Bosch FL engines Bosch BFL engines Motorpal (leak oil-less) B/FL engines DSLA 144 P547 5-hole DLLA 144 P521 5-hole DOP152P522 3898 170 Motorpal 17 07 53 Pressure for leak test of the injection valve below the previously read opening pressure
+1 +10
2011
Additional information Value see company plate Unit
07 52
bar
MPa
20
bar
08 00
ID No. 08 10 08 41
08 42
08 43
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56.5
mm
80.5
mm
78.4
mm
08 46
61.8
mm
08 50 08 51
08 73
09 00
ID No. 09 91
Cooling system
Name Gap dimension between running wheel and blower jacket inlet Additional information Value min. = 0.2 max. = 0.8 Unit
mm
12 00
ID No. 12 11 12 21
Other components
Name Tension of the single V-belt Tension of the single V-belt Additional information First assembly Check after 15 min running under load Value 450 50 300 20 Unit N N
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4 Technical data
4.1 Test and adjustment data Notes
2011
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2011
4
4.2
Technical data
Tightening specifications
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4 Technical data
4.2 Tightening specifications Notes
2011
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ID no.
Name
Remark
00001 Clamp holder on crankcase 00002 Clamp holder on adapter for assembly block 00003 Engine mount on crankcase elast. mounting
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4 Technical data
4.2 Tightening specifications
01000 Cylinder head
Pretightening value Re-tightening value + 80 Nm + 160 Nm + 90
2011
ID no.
Name
Remark In case of provability use max. 5 times. oil lubricated See tightening order
4
Tightening order 3-cylinder
39152 1
39153 1
10
39154 1
01002 Toggle lever block on cylinder head 01003 Lock nut on valve setting screw 01004 Cylinder head cover on cylinder head
21 Nm 20 2 Nm 8.5 Nm
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ID no.
Name
Remark in case of provability use max. 3 times with lube oil Central screw tighten alternately in case of provability use max. 5 times in case of provability use max. 5 times
02010 Main and fit bearing covers on crankcase 02015 Crankshaft gear wheel/flange hub on crankshaft 02020 Con rod bearing cover on con rod (crack con rod) Con rod bearing cover on con rod
130 Nm
30 Nm
30 Nm
03000 Crankcase
Pretightening value Re-tightening value
ID no.
Name
Remark Setting bolt for crankshaft lock Holder for setting bolt for crankshaft lock Renew CU sealing ring Setting bolt for control linkage lock Holder for setting bolt for control linkage lock Renew CU sealing ring
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4 Technical data
4.2 Tightening specifications
Pretightening value Re-tightening value
2011
Remark
ID no.
Name
03007 Locking screws M18 x 1.5mm - item 5 Note installation position of the sealing ring! Always renew after disassembly. M12 x 1.5mm - item 6 M30 x 1.5mm - item 7 Always renew after disassembly.
50 Nm
26 Nm 95 Nm
M20 x 1.5mm - item 10 Always renew after disassembly. M18 x 1.5mm - item 15 Always renew after disassembly. 03010 Rear cover on crankcase 03020 Front cover on crankcase 03030 Oil tray (plate), 2, 3 and 4-cylinder, Oil tray (cast), 4-cylinder Oil tray (cast), 4-cylinder Oil tray (cast), 4-cylinder 03031 Oil drain screw on lube oil tray 03060 Crankcase bleeding on: Front cover Cylinder head cover Cylinder head
56 Nm
33822 1
50 Nm 21 Nm 21 Nm 0.5 Nm 0.5 Nm 0.5 Nm 0.5 Nm 55 5 Nm 21 Nm 31 Nm 21 Nm 180 Nm Note tightening order! Note tightening order! Screws M8 x 16 mm Note tightening order! Screws M8 x 30 mm Note tightening order! Screws M8 x 5 mm Note tightening order! Cylinder head bolts Note tightening order! oiled Renew CU sealing ring
8.5 Nm
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Remark M12 x 20mm M12 x 30mm M12 x 35mm M12 x 55mm M12 x 70mm M12 x 75mm M12 x 95mm
180 Nm
45 Nm
60 Nm
22 Nm
9 Nm 9 Nm
ID no.
Name
Remark
04001 Camshaft toothed belt wheel on camshaft 04002 Start-up disc on camshaft 04052 Clamping roller on front cover 04053 Protective hood (toothed belt) on front cover
Central screw
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4 Technical data
4.2 Tightening specifications
05000 Speed governing
Pretightening value 9.2 Nm 6 0.6 Nm 16 1.6 Nm 4.5 Nm 6 0.6 Nm 8.5 Nm 9.2 Nm 4.6 0.4 Nm 10 1 Nm 10 1 Nm Lock nut Re-tightening value
2011
ID no.
Name
Remark Full load stop Minimum speed Screw spring pre-tension Shutoff stop Adapter capsule
05004 Lock nut on setting screw 05005 Lock nut on setting screw 05006 Lock nut on setting screw 05007 Lock nut on setting screw 05008 Lock nut on setting screw 05011 Speed governor on connection housing 05021 Regulator lever shaft on front cover 05022 No load capsule on front cover 05023 Adapter capsule on front cover 05024 Eccenter shaft on front cover 05025 Cap (speed adjustment lever) on front cover
4.5 Nm Valve crankshaft housing bleeding on front cover 05041 Lifting magnet (shutoff magnet) on front cover 05065 Lifting magnet (start volume release) on front cover 8.5 Nm 10 Nm
ID no.
Name
06001 Exhaust manifold on cylinder head 06020 Turbocharger on exhaust manifold 06024 Reducer on turbocharger
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Remark
06030 Air intake pipe on cylinder head Charge air on cylinder head 06094 Solenoid valve on LDA
ID no.
Name
Remark
07001 Injection valve on cylinder head 07002 Injection nozzles lock nut on nozzle holder (leak oil-less) Injection nozzles lock nut on nozzle holder 07003 Injection line on: Injection valve injection pump 07012 Injection pump on (Bosch/ Motorpal) crankcase 07015 Fuel supply line to injection pump 07024 Fuel pump on crankcase 07061 Overcurrent line to injection pump 07062 Overcurrent line to cylinder head bolt 07071 Locking screw on injection pump (Motorpal) 07082 Fuel filter console on crankcase 07087 Fuel filter console on holder
25 2.5 Nm
Union nut
21 Nm 29 Nm 21 Nm 29 Nm 8.5 Nm 45 5 Nm 21 Nm Hexagon bolt M8 x 50mm and hexagon nut M8 27 Nm Renew CU sealing rings Hollow screw DIN 7643-8 Piston pump Diaphragm pump Renew CU sealing rings Hollow screw
11/2004
9/14
4 Technical data
4.2 Tightening specifications
Pretightening value 22 Nm 8 Nm 9 1 Nm hand tight Re-tightening value
2011
Remark
ID no.
Name
07095 Charge pressure-dependent full load stop (LDA) on crankcase 07096 Cap on charge pressuredependent full load stop (LDA) 07099 Fuel filter on fuel filter console
Name
Remark Oil gasket lightly Screw on by hand and screw tight Torx screw
29 Nm
08044 Oil return pipe on turbocharger Oil return pipe on turbocharger 08046 Holder for stopper on crankcase Oil return pipe (ATL) holding plate on crankcase 08047 Oil return pipe (ATL) on crankcase 08048 Oil line to (control line): oil filter console Crankcase
11/2004
10/14
Remark Torx screw M8 Injection adjustment M6 x 60mm Hexagon head screw Renew sealing rings Note installation position Renew CU sealing rings Hexagon socket Oil pressure switch M10 x 1mm
08051 Oil cooler fastening screws 08053 Locking screw thermostat for injection adjuster on oil filter console 08054 Oil cooler connection on crankcase 08061 Transfer nipple on crankcase (heater connection) 08062 Locking screws M18 x 1.5 mm at transfer nipple (heater connection) 08072 Locking screw oil cooler thermostat on crankcase 08091 Oil pressure switch (locking screw) on crankcase 08093 Oil pressure sensor on crankcase 08094 Locking screw (oil pressure sensor) on crankcase 08095 Oil temperature sensor on crankcase 08096 Locking screw (oil temperature sensor) on crankcase 08098 Locking screw (oil pressure regulating valve) on crankcase 08099 Locking screw on crankcase (without air press lubrication)
13 Nm 111 11 Nm 50 Nm 50 Nm 13 1.5 Nm 20 +2 Nm 50 Nm
25 2.5 Nm 28 Nm 111 Nm 18 2 Nm 60 6 Nm 80 8 Nm Renew CU sealing rings Oil temperature sensor Renew CU sealing rings Oil pressure regulating valve M10 x 1mm M18 x 1.5mm M22 x 1.5mm
11/2004
11/14
4 Technical data
4.2 Tightening specifications
09000 Cooling system
Pretightening value 22 Nm 30 Nm 09042 Fan on flange hub, crankshaft 09065 Cooling blower jacket on generator 09066 Blower jacket on cylinder head 30 Nm 4 Nm 22 Nm 21 Nm 22 Nm 21 Nm Torx screw 8 x 20mm Re-tightening value
2011
ID no.
Name
Cooling blower on: air duct Cylinder head 09067 Blower jacket inlet on generator 09070 Stand plate on: crankcase Oil cooler 09087 Air duct cowling on: Cylinder head Stand plate 09089 Air duct on cooling blower 09098 Air duct on cylinder head
21 Nm 3 Nm 3 Nm 21 Nm +21 Nm
ID no.
Name
12001 Flywheel on crankcase 12030 Flange hub on toothed belt wheel, crankshaft 12031 V-belt pulley on toothed belt wheel, crankshaft 12041 V-belt tensioning roller (holder) on front cover
11/2004
12/14
12043 V-belt tensioning roller on holder 12046 V-belt pulley on fan mounting 12047 V-belt guard on front cover 12051 Hydraulic pump on hydraulic pump console 12052 Toothed belt tensioning roller on hydraulic pump console 12056 Protective hood on hydraulic pump console 12057 Hydraulic pump console on crankcase
ID no.
Name
Remark
13001 Starter on crankcase 13006 Starter console on crankcase 13009 Heat shield for starter 13010 Generator console on: crankcase Cylinder head Generator console on crankcase 13012 Generator on console
30 Nm 34 Nm 34 Nm
49
22 Nm 21 Nm
11/2004
13/14
4 Technical data
4.2 Tightening specifications
Pretightening value 22 Nm 21 Nm 13017 V-belt clamping bracket on front cover 13018 Generator console on cylinder head 13021 Pulley on generator 45 Nm 34 Nm 50 Nm 50 Nm 30 Nm 13031 Helical heater plug in: charge air line Suction pipe 13071 Charging current cable on starter 13081 Charging current cable on generator B+ 13082 Cable G1.D+ on generator 13083 Cable G1.W on generator 13092 Cable harness holder on crankcase Cable harness holder on: Starter crankcase 120 M10 x 110mm with built up fan drive Unit design with in-built fan drive Re-tightening value
2011
Remark with built up fan drive Unit design with built up fan drive Building machine design
ID no.
Name
8.5 Nm
M6
11/2004
14/14
2011
5
5.1
11/2004
1/6
2011
11/2004
2/6
11/2004
3/6
2011
Maintenance group Crankcase Cylinder head Exhaust system / Charging Electrical system Engine control crankcase Fuel system crankcase Cooling system Drive system crankcase Cylinder head Exhaust system / Charging Other components Crankcase Fuel system Fuel system Fuel system Fuel system Electrical system Electrical system Fuel system Electrical system Other components
11/2004
4/6
11/2004
2011
Maintenance group Fuel system Speed governing Electrical system Cylinder head Other components Exhaust system / Charging Other components Cylinder head Engine control Drive system Drive system Fuel system Engine control
Remove and install valves Renew camshaft sealing ring (opposite side to flywheel) Renew crankshaft sealing ring (opposite side to flywheel) Renew crankshaft sealing ring (flywheel side) Renew injection lines Renew toothed belt and clamping roller (new version of clamping roller) Renew toothed belt and clamping roller (old version of clamping roller) Renew toothed starter flywheel ring
W 04-04-12 W 12-06-03
11/2004
6/6
2011
5
5.2
11/2004
1/6
2011
11/2004
2/6
11/2004
2011
Maintenance group Crankcase Crankcase
Crankcase Crankcase Crankcase Crankcase Engine control Engine control Engine control
W 04-04-12 W 04-05-05 W 04-05-06 W 05-07-01 W 06-01-05 W 06-06-04 W 06-07-03 W 07-02-06 W 07-02-07 W 07-03-01 W 07-04-01 W 07-04-01 W 07-06-03 W 07-06-04
Engine control Engine control Engine control Speed governing Exhaust system / Charging Exhaust system / Charging Exhaust system / Charging Fuel system Fuel system Fuel system Fuel system Fuel system Fuel system Fuel system
11/2004
4/6
11/2004
5/6
2011
Maintenance group Cooling system Cooling system Cooling system Monitoring system Other components Other components Other components Other components Other components Other components Other components Electrical system Electrical system Electrical system Electrical system Electrical system
11/2004
6/6
2011
5
5.3
11/2004
1/10
2011
11/2004
2/10
W 00-02-06 Check compression Assemble and W 00-05-01 disassemble engine on engine block
W 13-03-02
01
Cylinder head
Job card Activity Check and set valve clearance Other job cards necessary for performing the activity
W 01-01-01
Remove and install toggle W 01-02-02 lever and toggle lever W 01-01-01 block Disassemble and complete, check toggle W 01-02-06 lever and toggle lever block W 01-04-04 Remove and install cylinder head
W 01-02-02
W 01-05-01 Remove and install valves W 01-04-04 W 01-05-04 Check valves W 01-06-03 Check valve guide I 01-07-07 Machine valve seat ring W 01-05-01 W 01-05-01 W 01-05-01 W 01-07-08 W 01-04-04
3/10
2011
Renew crankshaft sealing W 04-04-12 W 04-04-12 W 02-02-04 ring (opposite side to W 03-08-01 (old version) (new version) flywheel) W 02-03-01 Check con rod W 02-03-01 Check con rod (crack con rod) W 02-03-03 W 02-03-03
W 02-03-03
Remove and install piston W 02-09-03 bolt bush Remove and install crankcase W 02-01-07 W 02-09-03 W 03-08-01 W 03-09-01
W 02-04-01
W 02-09-03
Remove and install pistons W 01-04-04 W 02-10-03 W 08-04-06 and con rod
Remove and install pistons W 02-09-03 and con rod (crack con W 01-04-04 W 02-10-03 W 08-04-06 rod) W 02-09-07 Check piston W 02-10-03 Check piston rings and piston ring grooves W 02-09-03 W 02-09-03
W 02-15-01
11/2004
4/10
W 03-03-01 Check cylinder Remove and install front W 03-08-01 cover (opposite side to flywheel) Dismantle and complete front cover (speed W 03-08-03 governor with torque adaption) Dismantle and complete front cover (speed W 03-08-03 governor without torque adaption) W 03-09-01 Remove and install rear cover (flywheel side) Remove and install connection housing Remove and install camshaft bearing, check
W 04-03-01
W 03-08-01
5
W 03-08-01
W 03-09-04 W 08-04-07
W 03-09-04
W 03-11-01
W 01-02-02 W 02-04-01
5/10
2011
Renew camshaft sealing W 04-03-01 ring (opposite side to flywheel) Check engine control times
W 04-04-11
Renew toothed belt and W 12-02-01 W 12-02-01 W 04-04-12 clamping roller (old version (FL, BFL (FM, BFM W 12-08-03 of clamping roller) engines) engines) Renew toothed belt and W 12-02-01 W 12-02-01 (FL, BFL (FM, BFM W 12-08-03 W 04-04-12 clamping roller (new version of clamping roller) engines) engines) W 04-04-12 (old version) W 04-04-12 W 07-04-01 (new (Motorpal) version)
W 01-02-02 W 03-09-01 W 04-05-05 Remove and install camshaft W 07-04-01 W 07-11-01 (Bosch) W 04-05-06 Check camshaft W 04-05-05
05
Speed governing
W 05-07-01
06
W 06-01-05
Remove and install exhaust manifold Remove and install turbocharger Remove and install air intake pipe
W 06-06-04
W 06-06-04
W 06-07-03
W 06-01-05
11/2004
6/10
W 08-11-12 W 09-11-01 W 13-02-03 Remove and install lifting W 07-02-07 magnet for start volume release W 07-03-01 Renew injection lines W 07-04-01 Remove and install injection pumps (Bosch) W 08-08-02 W 07-03-01 W 07-06-04 W 07-10-06
W 07-04-01
Remove and install W 07-03-01 W 07-06-03 W 07-06-04 W 07-10-06 injection pumps (Motorpal) Determine the thickness of W 07-04-01 the shim gasket W 07-03-01 W 07-10-06 W 07-10-06 W 11-00-03 (Bosch) (Motorpal)
W 07-06-03
W 07-07-01
W 07-03-01
W 07-07-02
Checking and setting W 07-07-05 injection valves (leak fuel- W 07-07-01 less) W 07-08-01 Remove and install solenoid valve (LDA)
Remove and install charge W 07-08-02 pressure-depedent full load stop (LDA) Remove and install fuel W 07-10-06 lines (with Bosch injection W 08-08-02 pumps) W 07-10-06 Remove and install fuel lines (with leak fuel line) Remove and install fuel filter console
W 07-10-08
7/10
2011
Other job cards necessary for performing the activity
08
W 08-04-05
Remove and install lube oil W 04-04-12 pump (old version) Remove and install oil intake pipe Remove and install lube oil tray Remove and install oil cooler Remove and install oil filter cartridge
W 08-04-06
W 08-04-07
5
W 08-04-07 W 08-08-02
W 08-10-06
Remove and install oil W 08-11-02 pressure regulating valve, check W 08-11-07 Remove and install oil filter W 08-10-06 console Remove and install oil pressure switch Remove and install oil pressure sensor Remove and install oil temperature sensor Remove and install oil thermostat (oil cooler) W 08-08-02
W 08-11-08
W 08-11-09
W 08-11-11
W 08-11-12
Remove and install oil W 08-15-01 pressure line (turbocharger) W 08-15-02 Remove and install oil return line (turbocharger)
11/2004
8/10
Remove and install oil line W 08-16-01 for injection adjuster supply Remove and install oil temperature sensor (in W 08-16-02 engines with injection adjustment)
09
Cooling system
Job card Activity Remove and install cooling blower Dismantle and complete cooling blower, check Dismantle and complete fan drive Other job cards necessary for performing the activity W 12-02-01 (FL, BFL engines) W 09-11-01
W 09-11-01
W 09-11-02
W 09-13-01
11
Monitoring system
Job card Activity Remove and install lifting magnet (shutoff magnet) Other job cards necessary for performing the activity W 13-02-03 (FM, BFM engines)
W 11-00-03
W 12-02-06
12
Other components
Job card Activity Check V-belt, renew (in FL and BFL engines) Check V-belt, renew (in FM and BFM engines) Remove and install V-belt clamping roller W 12-02-01 W 12-02-01 (FL, BFL (FM, BFM engines) engines) Other job cards necessary for performing the activity
W 12-02-01
W 12-02-01
W 12-02-06
9/10
2011
Other job cards necessary for performing the activity
W 12-06-03
W 12-08-02
Remove and install W 12-02-01 W 12-02-01 toothed belt and clamping (FL, BFL (FM, BFM W 12-08-03 roller of the hydraulic engines) engines) pump
13
Electrical components
Job card Activity Remove and install cable harness Other job cards necessary for performing the activity
W 13-01-02
Remove and install W 13-02-03 generator (in FL and BFL engines) Remove and install W 13-02-03 generator and holder (in FM and BFM engines) W 13-03-02 Remove and install starter W 13-06-01 Remove and install helical heater plugs
W 12-02-01
W 12-02-01
11/2004
10/10
2011
Job cards
6
11/2004
1/2
11/2004
2/2
2011
W 00-02-06
Check compression
Tools
- Commercial tools 8005 - Compression tester 8189 - Torx tool kit - Special tools 100 120 - Connecting piece
References
- W 01-01-01 - W 07-07-01 - W 08-08-02
Check compression Check and set valve clearance Job card W 01-01-01. Remove injection valves Job card W 07-07-01. In FL, BFL engines Install oil cooler Job card W 08-08-02.
39104 0
Note
Use sealing ring from injection valve.
39105 0
11/2004
1/4
2011
Note
Note installation position.
07001
39106 0
39107 0
Connect compression tester to connection piece or adapter. Turn over engine with starter.
00 51
39102 0
11/2004
2/4
2011
The measured compression pressure depends on the starting speed during the measuring process and the altitude of the engine installation site. Limit values can therefore not be determined exactly. The compression measurement is only recommended as a reference measurement of all cylinders of an engine to each other. If more than 15% deviation has been determined, the cause should be determined by disassembling the cylinder unit concerned.
No.
Kompression in bar Compression value in bar Pression en bar Dat. _________ 10 15 20 25 30 35 40
Zyl. 1 2 3 4 5 6 7 8
Made in Germany
39102 0
Unscrew screw (1). Remove connection piece with sealing ring. In FL, BFL engines Remove oil cooler Job card W 08-08-02. Install injection valves Job card W 07-07-01.
39103 0
11/2004
3/4
2011
11/2004
4/4
2011
W 00-05-01
References
- W 13-03-02
Note
In the repair procedure shown here different customer scopes are not taken into consideration, i.e. add-on parts deviating from standard are not shown.
Auxiliary material
- Lifting gear - Support ropes - Eyebolts
Assemble engine on engine block Remove starter Job card W 13-03-02. Screw in eyebolt (1). Hang engine on suitable workshop crane.
6
1 1
39500 0
Unscrew screws (1) and remove engine bearing (2) of the Manifold side.
00 81
39501 0
11/2004
1/6
2011
2 1
39502 0
In BFL, BFM engines Unscrew screw (1) and remove holder. Remove oil return pipe (arrow).
34015 1
Mount clamping holder (1) on the Manifold side and tighten screws (2).
00001
39503 0
11/2004
2/6
2011
Mount clamping holder on engine assembly block. Fit counter plate (1). Insert screws and nuts (2).
00002
39504 0
Remove engine from assembly block. Screw in eyebolt. Hang engine on suitable workshop crane. Unscrew nuts (2), remove counter plate (1) and bolts.
39504 0
39503 0
11/2004
3/6
2011
39505 0
Note
Oil round sealing ring lightly
2 1
39502 0
In BFL, BFM engines Pull new round sealing rings onto screwed socket (arrow) and oil return pipe.
34266 1
11/2004
4/6
2011
Insert oil return pipe (arrow). Mount holder and tighten screw (1).
08044
34015 1
Unhook engine from workshop crane and unscrew eyebolt. Install starter Job card W 13-03-02
39501 0
11/2004
5/6
2011
11/2004
6/6
2011
W 01-01-01
Note
The standard valve clearance setting is possible: - On cold or warm engine after a cooling time of at least 0.5 h. - Oil temperature < 80 C.
Removal Unscrew screws (arrows), remove starter cylinder head cover (1) and gasket.
39131 0
Set engine to valve overlap Turn crankshaft until reaching valve overlap on cylinder no. 1.
01 63
39132 0
11/2004
1/4
2011
39133 0
Check valve clearance Arrangement of inlet and outlet valves. - IN = inlet valve - EX = outlet valve
EX
IN
EX
IN
EX
IN
EX
IN
39134 0
Check valve clearance setting with feeler gauge blade on the appropriate cylinder.
01 63 01 61 01 62
Note
The feeler gauge blade must go between the toggle lever sliding surface and the valve with little resistance.
39135 0
11/2004
2/4
2011
Setting valve clearance Loosen lock nut (1). Correct valve clearance by turning the setting screw (2).
Note
- If valve clearance is too small, unscrew the setting screw. - If valve clearance is too great, screw in the setting screw.
01 61 01 62
39136 0
Note
Do not turn the setting screw (2) when tightening the lock nut.
01003
1
39137 0
Assembly Clean the sealing surface on the cylinder head cover and cylinder head. Fit gasket.
Note
Note installation position, the gate (arrow) must face the front cover.
39138 0
11/2004
3/4
2011
39139 0
11/2004
4/4
2011
W 01-02-02
References
- W 01-01-01
Remove toggle lever and toggle lever block Unscrew screws (arrows). Remove cylinder head cover (1) and gasket.
39131 0
Unscrew screws (1) and remove toggle lever with toggle lever block (2).
Note
- Loosen screws evenly to avoid jamming the toggle lever blocks. - Set down the components in the order of installation.
2
39140 0
11/2004
1/4
2011
Note
Set down the components in the order of installation.
1 1
39141 0
Note
- Note the assignment of the stop rods. - The stop rod must be seated in the socket of the ram with the ball head.
1 1
39141 0
Install toggle lever and toggle lever block Loosen the lock nuts of the setting screws and turn back the setting screws. Mount toggle lever block (1).
Note
The ball heads must be seated in the sockets of the stop rods (arrows).
39142 0
11/2004
2/4
2011
Tighten (1) screws alternately.
Note
- Make sure that the stop rods are not under stress due to valve overlap when tightening the bolts. - Align toggle lever to the stop rods/valves.
01002
39143 0
Clean the sealing surface on the cylinder head cover and cylinder head. Fit gasket.
Note
Note installation position, the gate (arrow) must face the front cover.
39138 0
39139 0
11/2004
3/4
2011
11/2004
4/4
2011
W 01-02-06
Disassemble and complete, check toggle lever and toggle lever block
Tools
- Commercial tools Internal measuring device Micrometer gauge
References
- W 01-02-02
Dismantle toggle lever block Remove toggle lever and toggle lever block Job card W 01-02-02. Remove locking rings (1).
6
1
39144 0
39145 0
11/2004
1/4
2011
Note
If the wear limit is reached, change the toggle lever.
39032 0
Unscrew lock nut (1) and turn out setting screw (1).
39146 0
Check components for visible signs of wear. Check oil channels (arrows) for free passage.
39147 0
11/2004
2/4
2011
Turn setting screw (2) into the toggle lever and tighten the lock nut (1).
39146 0
Check the toggle lever axis Measure toggle lever diameter with micrometer gauge.
01 74
Note
If the wear limit is reached, the toggle lever block has to be changed.
39148 0
Complete the toggle lever block Push toggle lever (1) onto the toggle lever axle (2).
Note
- Oil the toggle lever axle (2) lightly. - The toggle lever sliding surface (3) must face the side with the notch (arrow).
39149 0
11/2004
3/4
2011
Note
Pay attention to correct fit of the locking ring in the groove. Install toggle lever and toggle lever block Job card W 01-02-02.
1
39150 0
11/2004
4/4
2011
W 01-04-04
References
- W 01-02-02 - W 06-07-03 - W 07-07-01 - W 09-11-01 - W 13-02-03
Remove cylinder head Remove air intake pipe Job card W 06-07-03. Remove injection valve Job card W 07-07-01. Remove toggle lever and toggle lever block Job card W 01-02-02. In FM, BFM engines Remove generator Job card W 13-02-03.
39445 0
Note
Put down the components in the order of installation, note order of cylinders.
39151 0
11/2004
1/8
2011
39155 0
Note
- The piston overlap must be measured on all pistons to determine the cylinder head gasket. - The cylinder head gasket must be selected according to the greatest measured piston overlap.
39208 0
Determine piston UT Turn crankshaft until the piston closes flush with the crankcase.
Note
Turn crankshaft in direction of rotation of engine.
39156 0
11/2004
2/8
2011
Mount shim (1) and measuring bridge (2) on crankcase. Insert meter in measuring bridge and position the stylus with pre-tension on the piston base (arrow). Turn the crankshaft on evenly until the reversal point of the pointer on the meter is reached. The piston is now in UT.
39157 0
Determine piston overlap Move measuring bridge and shim. Place the stylus of the meter under pre-tension on the sealing surface of the crankcase (arrow). Adjust meter to "0".
39158 0
Note
Schematic representation for measuring the piston overlap at the points "1" and "2".
2
34151 1
11/2004
3/8
2011
Note
- Measuring points, see schematic diagram. - The stylus may not be positioned on the labeling of the piston. Note the greatest measured value.
39159 0
Select the cylinder head gasket according to the greatest measured piston overlap.
02 75 02 76 02 77
Example: Piston overlap = 0.73 mm, corresponds to cylinder head gasket with 2 notches (arrow).
39160 0
Install cylinder head Make sure the clamping pins (arrows) are in place.
39161 0
11/2004
4/8
2011
Mount new cylinder head gasket.
Note
- Sealing surfaces for the cylinder head gasket must be clean and free of oil. - Identification OBEN / TOP must face up.
39162 0
Mount cylinder head, oil cylinder head bolts lightly and tighten.
Note
Cylinder head bolts can be used a maximum 5 times in case of provability.
01 98
39163 0
39152 0
11/2004
5/8
2011
39153 0
10
39154 0
39445 0
11/2004
6/8
2011
In FL, BFL engines Install cooling blower Job card W 09-11-01. Install toggle lever and toggle lever block Job card W 01-02-02. Install injection valve Job card W 07-07-01. Install air intake pipe Job card W 06-07-03.
39234 0
11/2004
7/8
2011
11/2004
8/8
2011
W 01-05-01
References
- W 01-04-04
Remove valves Remove cylinder head Job card W 01-04-04. Install clamping block (1) on clamping plate (2). Install cylinder head on clamping block.
6
1
2
39164 0
Install valve assembly lever (1). Press down the valve spring with the valve assembly lever and remove both clamping cones (2). Remove valve spring plates, valve springs and valves. Remove valve assembly lever.
39165 0
11/2004
1/4
2011
39166 0
Clean cylinder head, check and inspect for damage. Check components for visible signs of damage.
39167 0
Note
If the wear limit is reached, the valve spring has to be changed.
01 51
35856 1
11/2004
2/4
2011
Insert valve, hold tight and push the protective sleeve (1) onto the valve shaft.
Note
- Oil the valve shaft slightly. - Cover the valve V-grooves with the protective sleeve (1) or adhesive foil before installing the valve shaft seal every time.
33889 1
Push the new valve shaft seal over the protective sleeve (arrow).
33890 1
Remove the protective sleeve. Press the valve shaft seal in with the assembly tool (1) until it touches.
39168 0
11/2004
3/4
2011
2
39169 0
Install valve assembly lever. Press down the valve spring with the valve assembly lever and insert both clamping cones (1).
Note
Pay attention to correct fit of the clamping cones in the valve V-groove.
39170 0
Remove valve assembly lever Remove cylinder head from clamping block. Install cylinder head Job card W 01-04-04.
39171 0
11/2004
4/4
2011
W 01-05-04
Check valves
Tools
- Commercial tools Micrometer gauge Caliper gauge
References
- W 01-05-01
Note
- Clean all valves. - If the wear limit is reached, the valve has to be changed.
Valve shaft diameter Remove valves Job card W 01-05-01. Measure valve shaft diameter with micrometer screw.
01 31 01 32
42182 0
Valve edge strength Measure valve edge thickness with caliper gauge.
01 35 01 36
42183 0
11/2004
1/2
2011
42184 0
11/2004
2/2
2011
W 01-06-03
References
- W 01-05-01
Note
- New valves are used for testing. - If the wear limit is reached, the valve guide has to be changed.
Check valve guide Remove valves Job card W 01-05-01. Check valve guide for visible signs of wear. Attach magnetic measuring stand and insert meter. Insert new valve. Apply stylus to the valve head with pre-tension (arrow) and set meter to 0.
33881 1
Measure valve shaft clearance Move valve to and fro in direction of arrow.
Note
- The end of the valve shaft must be flush with the valve guide to measure the valve shaft clearance. - The whole tilt angle must be taken into consideration.
01 33 01 34
39172 0
11/2004
1/2
2011
39173 0
11/2004
2/2
2011
I 01-07-07
References
- W 01-05-01 - W 01-07-08
Note
- The valve seat ring must be reworked in the installed state in the cylinder head. - For handling the valve seat rotating device, observe the respective manufacturers operating manual.
Check valve seat ring Check valve lag Job card W 01-07-08. Remove valves and valve shaft seals Job card W 01-05-01.
39175 0
Note
If the wear limit of valve seat and valve lag is not yet reached and there are no burnthroughs, blow-throughs, tears or marks, it is possible to rework the valve seat ring for further use.
39167 0
11/2004
1/4
2011
Note
Observe different valve seat angles.
01 47
01 48
39353 0
Turn out the valve seat carefully until it is level all round.
Note
- Do not remove more material than necessary from the valve seat. - Check the valve seat after every step.
39353 0
39379 0
11/2004
2/4
2011
Note
The valve set is a little wider after reworking. If necessary, the valve seat width can be reduced by reworking the outer correction angle (1) and also the inner correction angle (2) if necessary.
01 41 01 42
2
39393 0
Check contact pattern Coat the sitting surface of the valve cone thinly with varnish. Insert valve and turn 45 to 90. Remove the valve and check the contact pattern.
Note
A continuous surrounding contact between the valve cone and the valve seat ring must be guaranteed at the greatest valve seat diameter (outer contact) with a radial contact percentage of 60 to 100%.
39461 0
Clean valve and valve seat ring. Check valve lag Job card W 01-07-08.
Note
Do not rework valve seat with lapping compound.
39052 0
11/2004
3/4
2011
11/2004
4/4
2011
W 01-07-08
References
- W 01-04-04
Note
If the wear limit is reached, the valve seat ring or the valve itself must be changed, both together if necessary.
Check valve lag Remove cylinder head Job card W 01-04-04. Install clamping block (1) on clamping plate (2). Mount the cylinder head on the clamping block.
6
1
2
39164 0
Measure valve lag with depth measuring appliance from the valve head to the cylinder head sealing surface.
01 45 01 46
39175 0
11/2004
1/2
2011
2
39164 0
11/2004
2/2
2011
W 02-01-07
Check crankcase
Tools
- Commercial tools Magnetic measuring stand Micrometer gauge Internal measuring device Prisms Hardness tester - Special tools 100 400 - Meter
References
- W 02-04-01
Note
The rework stages are marked on the outer contour of the crankshaft face on the flywheel side. H = ground main bearing pin P = ground con rod bearing pin
Note
If the crankshaft is worn it is possible to have the crankshaft repaired in our Service Centers. Check bearing pin hardness Remove crankshaft Job card W 02-04-01. Place the crankshaft on prisms.
39176 0
Note
The measured values must be converted according to the table of the measuring instrument.
02 07
39177 0
11/2004
1/4
2011
36424 1
Check the diameter of the main bearing pins Measure main bearing pin with micrometer screw.
Note
Measuring points, see schematic diagram
02 03
02 04
02 05
02 06
39178 0
Check the diameter of the lifting bearing journal Measure lifting bearing journal with micrometer gauge.
Note
Measuring points, see schematic diagram
02 22
02 23
02 24
02 25
39179 0
11/2004
2/4
2011
Check runout Attach magnetic measuring stand and insert meter. Apply stylus to the main bearing pin with pre-tension (arrow) and set meter to 0. Turn crankshaft evenly and check shells.
02 26
39180 0
Measure fit bearing width Set micrometer gauge to 35 mm. Push the internal measuring device between the test surfaces of the micrometer gauge and set to 0.
35825 1
Measure fit bearing width with internal measuring device between the contact surfaces of the starting rings. Note the measured value (dimension A).
02 11 02 12 02 13
Note
The dimension "A" is required for determining the axial clearance.
39181 0
11/2004
3/4
2011
Note
The dimension "B" is required for determining the axial clearance.
35827 1
Visual inspection Visually inspect the running surfaces (arrows) of the shaft sealing rings. Install crankshaft Job card W 02-04-01.
39182 0
11/2004
4/4
2011
W 02-02-02
References
- W 12-06-01
Remove crankshaft sealing ring Remove flywheel Job card W 12-06-01. Loosen the crankshaft sealing ring (arrow) in its seat with a pin.
39506 0
Carefully drill a hole (at least 3 mm ) diameter in the crankshaft sealing ring.
Note
- Coat the drill thickly with grease so that no drill chips fall into the crankcase. - Do not damage the rear cover and crankshaft.
39507 0
11/2004
1/4
2011
39508 0
Remove crankshaft sealing ring with suitable tool, e.g. assembly lever. Visually inspect the crankshaft flange and rear cover.
39509 0
Install crankshaft sealing ring Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. Fit the crankshaft sealing ring (1) to the assembly sleeve (2).
2 1
Note
The sealing lip must face the crankshaft in assembly.
39510 0
11/2004
2/4
2011
Note
Installation depthe X = approx. 2.5 mm of the crankshaft sealing ring.
X
39352 0
Note
Note installation depth. Install flywheel. Job card W 12-06-01.
39511 0
11/2004
3/4
2011
11/2004
4/4
2011
W 02-02-04
References
- W 03-08-01 - W 04-04-12 old version - W 04-04-12 new version
Remove crankshaft sealing ring Remove toothed belt and clamping roller, loosen camshaft toothed belt wheel Job card W 04-04-12 old version. Job card W 04-04-12 new version. Remove crankshaft toothed wheel Job card W 03-08-01. Loosen crankshaft sealing ring in its seat with a pin.
39650 0
Carefully drill a hole (at least 3 mm ) diameter in the crankshaft sealing ring.
Note
- Coat the drill thickly with grease so that no drill chips fall into the crankcase. - Do not damage the front cover and crankshaft.
39651 0
11/2004
1/4
2011
39652 0
Remove crankshaft sealing ring with suitable tool, e.g. assembly lever. Visually inspect the running surface of the crankshaft flange and front cover.
39653 0
Install crankshaft sealing ring Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. Fit the crankshaft sealing ring (1) to the assembly tool (2).
1 2
Note
The sealing lip must face the crankshaft in assembly.
39515 0
11/2004
2/4
2011
Mount the crankshaft sealing ring with the assembly tool and turn in the screw.
39654 0
Note
The installation depth of the crankshaft sealing ring is determined by the assembly tool. Unscrew screw and remove assembly tool. Install crankshaft toothed wheel Job card W 03-08-01. Install toothed belt and clamping roller, fix camshaft toothed belt wheel Job card W 04-04-12 old version. Job card W 04-04-12 new version.
39655 0
11/2004
3/4
2011
11/2004
4/4
2011
W 02-03-01
References
- W 02-03-03
Note
The con rod is removed and the piston disassembled.
Check piston bolt bush Prepare internal measuring device Mount probe bolt for the appropriate measuring range in the internal measuring device. Mount meter with approx. 1 mm pre-tension in the internal measuring device. Set micrometer gauge to - 26 mm in FL/M engines - 30 mm in BFL/M engines. Balance the internal measuring device between the test surfaces of the micrometer gauge and set the meter to the reversal point of the pointer to 0.
34768 1
Note
Schematic representation for measuring the piston bolt bush at the points a and b in the levels 1 and 2.
37239 0
11/2004
1/8
2011
Note
- Piston bolt bush pressed in. - Measuring points, see schematic diagram.
02 43
34770 1
Check diameter of the piston bolt Measure piston bolt with micrometer gauge.
02 61
35908 1
Example:
Dimension "A" = Dimension B Piston bolt clearance 26.035 mm 26.000 mm 0.035 mm
Note
The piston bolt clearance is given by the difference between the piston bolt bush internal diameter "A" and the diameter of the piston bolt "B".
02 45
11/2004
2/8
2011
Check the con rod bearing bore Mount con rod bearing cover on con rod.
Note
The numeric identification (1) on the con rod and the con rod bearing cover must be identical and be opposite each other in assembly.
39322 0
Tighten nuts.
Note
Use a twelve-edge box wrench.
02020
39323 0
Prepare internal measuring device Mount probe bolt for the appropriate measuring range in the internal measuring device. Mount meter with approx. 1 mm pre-tension in the internal measuring device. Set micrometer gauge to 58.50 mm. Balance the internal measuring device between the test surfaces of the micrometer gauge and set the meter to the reversal point of the pointer to 0.
36094 1
11/2004
3/8
2011
37239 0
Measure con rod bearing bore with internal measuring device. Insert internal measuring device in the con rod bearing bore. Balance the internal measuring device respectively at the given measuring points and read the measured value at the reversal point of the pointer.
Note
If the measured values deviate slightly, additional measurements must be made with new bearing shells.
02 55
39324 0
Check con rod bearing shell internal diameter Unscrew nuts and remove con rod bearing cover. Insert con rod bearing shell in the con rod.
Note
- Note the assignment of the bearing shells. - The twist protection (1) must engage in the groove (2).
39325 0
11/2004
4/8
2011
Insert con rod bearing shell in the appropriate con rod bearing cover.
Note
The twist protection (1) must engage in the groove (2).
39326 0
Mount the con rod bearing cover and tighten the nuts.
Note
The numeric identification (1) on the con rod and the con rod bearing cover must be identical and be opposite each other in assembly.
1
39327 0
Tighten nuts.
Note
Use a twelve-edge box wrench.
02020
39328 0
11/2004
5/8
2011
36094 1
Note
Schematic representation for measuring the con rod bearing shell internal diameter at the points a and b in the levels 1 and 2.
37239 0
Measure con rod bearing shell internal diameter with internal measuring device. Insert internal measuring device between the con rod bearing shells. Balance the internal measuring device respectively at the given measuring points and read off the measured value at the reversal point of the pointer.
Note
- If the values are up to max. 0.015 mm above the bearing tolerances, the con rod can be used further. - If the wear limit is reached, the con rod has to be changed.
02 52 02 53 02 54
39329 0
11/2004
6/8
2011
Determine con rod bearing clearance
Note
The con rod bearing clearance is given by the difference of the con rod bearing shell internal diameter A and the diameter of the lifting bearing journal B.
02 56
02 57
Check con rod parallelism Check con rod without bearing shells on the con rod test device. Permissible deviation "a" = max. 0.03 mm at a distance of "X" = 100 mm.
35880 1
Check con rod right-angledness Permissible deviation "A" to "B" = max. 0.03 mm at a distance of "X" = 100 mm.
Note
Aligning the con rod is not permissible.
35881 1
11/2004
7/8
2011
11/2004
8/8
2011
W 02-03-03
Note
- The con rod is removed and the piston disassembled. - The piston bolt bush must be mechanically machined after assembly.
References
- W 02-09-03
Remove piston and con rod Job card W 02-09-03. Remove piston bolt bush Insert extraction socket (1) in piston bolt bush. Place counterbearing (2) with the open side on the con rod and insert the screw (3). Fit washer and tighten nut (4).
6
4
3 2 1
Note
- 131 340 for FL/M engines. - 131 350 for BFL/M engines.
39330 0
Pull out piston bolt bush. Dismantle disassembly tool and remove piston bolt bush.
39331 0
11/2004
1/4
2011
Note
Pay attention to matching of the oil bores (1) in the piston bolt bush and the con rod.
39332 0
Insert extraction socket (1) in new piston bolt bush. Place counterbearing (2) with the closed side on the con rod and insert the screw (arrow). Fit washer and tighten nut.
39333 0
Pull in piston bolt bush flush. Remove disassembly tool. Check matching of oil bores in the piston bolt bush and con rod again.
39334 0
11/2004
2/4
2011
Note
The piston bolt bush must be mechanically machined after assembly.
02 61 02 43 02 45
33855 1
11/2004
3/4
2011
11/2004
4/4
2011
W 02-04-01
References
- W 02-01-07 - W 02-09-03 - W 03-08-01 - W 03-09-01
Note
Only in FL, FM engines When replacing the crankshaft and/or crankcase, the piston class must be redetermined.
Auxiliary material
- DEUTZ DW 74
Remove crankshaft Remove rear cover (flywheel side) Job card W 03-09-01. Remove front cover (opposite side to flywheel) Job card W 03-08-01. Unscrew screws (1) and remove oil intake pipe (2).
39335 0
39188 0
11/2004
1/10
2011
Note
- Use a twelve-edge box wrench. - Put down the con rod bearing cover in the order of installation, note order of cylinders. - Do not turn the crankshaft. Remove con rod bearing cover and con rod bearing shell.
39336 0
Remove fit bearing and all main bearing covers Unscrew screws (1).
39337 0
Remove fit bearing cover (1), bearing shell and both startup ring halves (arrows). Remove main bearing cover (2) and bearing shells.
Note
Put down the components in the order of installation, note order of cylinders.
39338 0
11/2004
2/10
2011
Remove crankshaft.
39339 0
Remove all main bearing shells (1) and all con rod bearing shells (2).
Note
Put down the components in the order of installation, note order of cylinders. Check components for visible signs of wear. Check axial clearance of crankshaft Job card W 02-01-07.
39340 0
Note
When replacing the crankshaft and/or crankcase, the distance from the cylinder head sealing surface to the highest point of the lifting bearing pin in UT position must be redetermined to define the piston class. Remove and install pistons and con rod Job card W 02-09-03.
39251 0
11/2004
3/10
2011
Note
- Note the assignment of the bearing shell. - The twist protection (1) must engage in the groove (2).
39341 0
Note
- Note the assignment of the main bearing cover. - The twist protection (1) must engage in the groove (2).
37043 1
Note
- Note the assignment of the bearing shell. - The twist protection (1) must engage in the groove (2).
39342 0
11/2004
4/10
2011
Insert con rod bearing shell in the appropriate con rod bearing cover.
Note
- Note the assignment of the bearing shell. - The twist protection (1) must engage in the groove (2).
39343 0
39344 0
Oil all bearing surfaces on the bearing pin and bearing shells lightly. Insert the crankshaft carefully in the crankcase.
Note
Do not jam the con rods when inserting the crankshaft.
39339 0
11/2004
5/10
2011
Note
- The installation position of the fit bearing cover is given by the numeric identification (1): Number 1 in 2-cylinder Number 2 in 3-cylinder Number 3 in 4-cylinder - The oil groove (2) must face the face mirror of the crankshaft.
2
39345 0
Install fit bearing and main bearing covers Insert fit bearing cover (1) and main bearing cover (2) according to the numbering.
Note
Note assignment and installation position. - Insert bearing cover with number "1" on flywheel side. - The bevel (arrow) must face the front cover.
1
39346 0
Oil lightly and tighten all screws (1) of the fit bearing and main bearing covers.
Note
Screws can be used a max. 3 times in case of provability, otherwise always change them.
02010
39347 0
11/2004
6/10
2011
Install all con rod bearing covers Pull the con rods carefully onto the lifting bearing journal.
39348 0
Note
- Note the assignment of the con rod bearing cover. - The numeric identification on the con rod bearing cover and the con rod must be identical and be opposite each other in assembly (1). - The numeric identification is facing the operating side.
39349 0
Tighten nuts.
Note
- Con rod bolts and nuts can be used a max. 5 times in case of provability, otherwise always change them. - Use a twelve-edge box wrench.
02020
39350 0
11/2004
7/10
2011
39351 0
Note
Do not move sealant when mounting the oil intake pipe.
08015
39335 0
39188 0
11/2004
8/10
2011
Turn the crankshaft carefully in the direction of rotation of the engine (clockwise) until it touches the setting bolts. Install rear cover (flywheel side) Job card W 03-09-01. Install front cover (opposite side to flywheel) Job card W 03-08-01.
39130 0
11/2004
9/10
2011
11/2004
10/10
2011
W 02-09-03
References
- W 01-04-04 - W 02-10-03 - W 08-04-06
Notes on piston classes of the pistons When replacing a piston, make sure you use the same piston class.
Note
- The pistons are divided into piston classes by different compression values. - The piston classes are marked on the base of the piston by "A" or "B" (1).
39249 0
Note
- For FL- and FM engines pistons with different compression values are available. - In BFL and BFM-engines pistons with piston class "A" (1) are used exclusively.
20 97
39174 0
11/2004
1/8
2011
1
39219 0
Remove con rod bearing cover Set lifting bearing journal in the lower dead point. Unscrew nuts (1).
Note
- Use a twelve-edge box wrench. - Put down the components in the order of installation, note order of cylinders.
00 81
Remove con rod bearing cover (2) and con rod bearing.
39220 0
Note
Set down the components in the order of installation, note cylinder order.
00 81
39221 0
11/2004
2/8
2011
Remove con rod bearing shells (1). Check components for visible signs of wear.
1 1
39240 0
Remove piston from con rod. Insert disassembly tool (1) in the piston bolt.
6
1
Caution!
!
Risk of injury! The spring ring jumps off. Always use the disassembly tool.
39244 0
Place suitable tool in recess (1). Remove spring rings (2) on both sides and press out piston bolt (3).
Note
The tools are not inserted for a better representation. Check components for visible signs of wear.
1 2
3
39248 0
11/2004
3/8
2011
Note
If the crankshaft and/or the crankcase are replaced, the piston class must be redetermined for every single cylinder. Place lifting bearing journal of the respective cylinder in the upper dead point (UT).
39250 0
Measure the distance with the depth measuring appliance, from the cylinder head sealing surface to the highest point of the lifting bearing journal in UT position.
Note
The sealing surface must be clean. Read and note measured value.
39251 0
Note
In undermeasure steps of the crankshaft 0.125 must be added to the values in the technical data.
39249 0
11/2004
4/8
2011
Complete the con rod and the piston Insert a spring ring.
Note
- The ring joint must face the piston base, X = +/- 20 - Pay attention to correct fit of the locking ring in the groove.
39257 0
6
6010
Note
The symbol flywheel/crankshaft (1), on the piston base, must face left and the numeric identification (2) on the con rod up.
39259 0
Oil lightly and press in the piston bolt. Insert the second spring ring.
Note
- The ring joint must face the piston compression bolt. - Pay attention to correct fit of the spring ring in the groove.
39260 0
11/2004
5/8
2011
Note
- Note the assignment of the bearing shells. - The twist protection (1) must engage in the groove (2).
39282 0
Insert con rod bearing shell in the appropriate con rod bearing cover.
Note
The twist protection (1) must engage in the groove (2).
39283 0
Arrange piston ring joints offset by about 120. Check piston rings and piston ring grooves Job card W 02-10-03.
36216 1
11/2004
6/8
2011
Oil cylinder running surface, piston, piston rings and lifting bearing journal lightly. Clamp piston rings with piston ring tensioning band (1).
Note
Do not turn the piston rings any more.
39284 0
Note
- Note the cylinder assignment of the piston. - Note the identification (1) of the installation position on the piston base, the symbol flywheel/crankshaft must face the flywheel. - The piston ring tensioning band must lie flat on the crankcase. Push the piston into the cylinder with the con rod.
39285 0
Note
Do not jam the con rod with the crankshaft.
39286 0
11/2004
7/8
2011
Note
- Note the assignment of the con rod bearing cover. - The numeric identifications (1) on the con rod and the con rod bearing cover must be identical and opposite each other when assembled. - The numeric identification is facing the operating side.
39287 0
Tighten nuts.
Note
- Con rod bolts and nuts can be used a max. 5 times in case of provability, otherwise always change them. - Use a twelve-edge box wrench.
02020
39290 0
Insert oil dipstick (1). Install oil intake pipe. Job card W 08-04-06. Install cylinder head Job card W 01-04-04.
1
39219 0
11/2004
8/8
2011
W 02-09-07
Check piston
Tools
- Commercial tools Micrometer gauge Internal measuring device - Special tools 100 400 - Meter
References
- W 02-09-03
Note
If the wear limit is reached, the piston has to be changed.
Check the piston bolt bore Remove piston from con rod. Job card W 02-09-03.
39054 0
Prepare internal measuring device Mount probe bolt for the appropriate measuring range in the internal measuring device. Mount meter with approx. 1 mm pre-tension in the internal measuring device. Set micrometer gauge to - 26 mm in FL/M engines - 30 mm in BFL/M engines. Balance the internal measuring device between the test surfaces of the micrometer gauge and set the meter to the reversal point of the pointer to 0.
34768 1
11/2004
1/4
2011
37239 0
Measure piston bolt bore with internal measuring device. Insert the internal measuring device in the piston bolt bush. Balance the internal measuring device respectively at the given measuring points and read off the measured value at the reversal point of the pointer.
Note
Measuring points, see schematic diagram.
02 78
36484 1
Note
Schematic representation for measuring the piston diameter at the measuring points 1, 2 and 3, transverse to the piston bolt bore.
3 2 1
37244 0
11/2004
2/4
2011
Measure piston diameter with micrometer gauge.
Note
Measuring points, see schematic diagram.
02 71 02 72 02 73
39055 0
11/2004
3/4
2011
11/2004
4/4
2011
W 02-10-03
References
- W 02-09-03
Check piston rings and piston ring grooves Remove piston from con rod. Job card W 02-09-03. Set universal piston ring pliers to the piston diameter.
02 71
39212 0
39213 0
11/2004
1/4
2011
33866 1
If there is a gap (S) between the trapezoidal wear gauge and piston, the piston is still usable.
33867 1
If the trapezoidal groove wear gauge is touching the piston (arrow), the piston must be changed.
33868 1
11/2004
2/4
2011
Check the piston ring joint clearance Insert the piston ring (1) in the cylinder.
Note
Align the piston ring in the cylinder by pushing the piston.
39214 0
Note
If the wear limit is reached, change the piston ring.
02 84 02 85 02 86
39215 0
Note
- Order and position of the piston rings seen from the piston base. - On the piston rings (1, 2 and 3) the identification Top must face the combustion chamber. Rectangular ring in FL/M engines. Double trapeze ring for BFL/M engines. Minute ring. Roof chamfer ring with hose spring.
1 2 3
1. 1. 2. 3.
39216 0
11/2004
3/4
2011
Note
Set spring joint of the roof chamfer ring 180 to the ring joint.
39217 0
Check the piston ring axial clearance Measure piston ring axial clearance in the piston ring groove with a feeler gauge.
Note
- Do measurement with new piston rings. - In BF engines, only check axial clearance with feeler gauge in piston ring groove 2 and 3. - If the wear limit is reached, the piston has to be changed.
02 87 02 88 02 89
39218 0
11/2004
4/4
2011
W 02-15-01
References
- W 02-04-01
Remove piston cooling nozzles Remove crankshaft Job card W 02-04-01. Press out piston cooling nozzle (1) with a suitable tool (2).
39210 0
Install piston cooling nozzles Clean bores for piston cooling nozzles in the crankcase. Press in piston cooling nozzle (1) with suitable tool to the stop. Install crankshaft Job card W 02-04-01.
39211 0
11/2004
1/2
2011
11/2004
2/2
2011
W 03-01-11
Crankcase W 03-01-11
Remove bleed valve Unscrew screw (1) and remove bleed valve (2). Clean components and check for visible signs of wear.
39028 0
Pull new round sealing ring (1) onto bleed valve (2).
2 1
39029 0
11/2004
1/4
Crankcase W 03-01-11
Install bleed valve Mount bleed valve (2) and press in.
2011
Note
The bleed valve must contact the front cover evenly. Tighten screw (1).
03060
39028 0
In BFL, BFM engines Remove bleed valve Unscrew screw (1) and remove bleed valve (2). Clean components and check for visible signs of wear.
34038 1
Pull new round sealing ring (1) onto bleed valve (2).
2 1
39029 0
11/2004
2/4
2011
Install bleed valve Mount bleed valve (1) and press in.
Crankcase W 03-01-11
Note
The bleed valve must touch the cylinder head cover evenly. Tighten screw.
03060
34163 1
11/2004
3/4
Crankcase W 03-01-11
Notes
2011
11/2004
4/4
2011
W 04-03-01
References
- W 04-04-12 (old version) - W 04-04-12 (new version)
Remove camshaft sealing ring Remove toothed belt and clamping roller, loosen camshaft toothed belt wheel Job card W 04-04-12(old version) Job card W 04-04-12(new version) Unscrew center screw (1) with washer (2) and remove the camshaft toothed belt wheel (3).
2 1
Note
There is no washer (2) on the camshaft toothed belt wheel with torsional vibration damper.
39243 0
39656 0
11/2004
1/4
2011
Note
- Coat the drill thickly with grease so that no drill chips fall into the crankcase. - Do not damage the front cover and crankshaft.
39657 0
39658 0
Pull out crankshaft sealing ring with assembly lever. Visually inspect the running surface of the crankshaft flange and front cover.
39659 0
11/2004
2/4
2011
Install camshaft sealing ring Oil the sealing lip of the new camshaft sealing ring lightly with engine oil. Fit the camshaft sealing ring (1) to the assembly tool (2).
1 2
Note
The sealing lip must face the camshaft in assembly.
39515 0
Mount the camshaft sealing ring with the assembly tool and turn in the screw.
39660 0
Note
The installation depth of the crankshaft sealing ring is determined by the assembly tool. Unscrew screw and remove assembly tool.
39661 0
11/2004
3/4
2011
Note
- There is no washer (2) on the camshaft toothed belt wheel with torsional vibration damper. - All connections must be clean and oil free. Install toothed belt and clamping roller, fix camshaft toothed belt wheel. Job card W 04-04-12 (old version) Job card W 04-04-12 (new version)
2 1
39243 0
11/2004
4/4
2011
W 03-03-01
Crankcase W 03-03-01
Check cylinder
Tools
- Commercial tools Internal measuring device Micrometer gauge - Special tools 100 400 - Meter
Note
- The crankshaft bearing cover must be mounted properly to measure the cylinder. - If the wear limit is reached, it is possible to rework the crankshaft for further use. Use pistons and piston rings according to the repair stage.
References
- W 01-04-04
Remove cylinder head Job card W 01-04-04. Check cylinder Check cylinder for visible signs of wear.
39239 0
Check the cylinder running surface Prepare internal measuring device. Mount probe bolt for the appropriate measuring range in internal measuring device. Install meter with approx. 1 mm pre-tension in the internal measuring device. Set micrometer gauge to 94 mm. Balance internal measuring device between the test surfaces of the micrometer gauge and set the meter at the reversal point of the pointer to 0.
36094 1
11/2004
1/2
Crankcase W 03-03-01
Note
Schematic representation for measuring the cylinder running surface at the points a and b in the levels 1 - 3".
2011
1
a b
2
a b
39100 0
Measure cylinder with internal measuring device. Insert internal measuring device in the cylinder. Balance the internal measuring device respectively at the given measuring points and read off the measured value at the reversal point of the pointer.
Note
Measuring points, see schematic diagram.
03 31 03 41 03 32 03 42
39241 0
11/2004
2/2
2011
W 03-08-01
Crankcase W 03-08-01
Auxiliary material
DEUTZ DW 67
References
- W 04-03-01 - W 04-04-12(new version) - W 04-04-12 (old version) - W 08-04-05 - W 08-08-02
Remove front cover Remove toothed belt and clamping roller, loosen camshaft toothed belt wheel Job card W 04-04-12(new version) Job card W 04-04-12(old version)
2 1
Remove camshaft toothed belt wheel Unscrew center screw (1) with washer (2) and remove the camshaft toothed belt wheel (3).
Note
There is no washer (2) on the camshaft toothed belt wheel with torsional vibration damper.
39243 0
Note
The fixing bolts (1) must engage the bores (2).
1
39374 0
11/2004
1/12
Crankcase W 03-08-01
Mount holder.
2011
Note
- The fixing bolts (1) must engage the bores (2). - Do not turn the crankshaft.
39375 0
Note
Do not turn the crankshaft.
39293 0
Note
Snap in setting bolts (1) in CCW position.
39294 0
11/2004
2/12
2011
Hold the force multiplier and loosen the center screw. Remove the force multiplier, holder and intermediate disc.
Crankcase W 03-08-01
39460 0
Note
An adapter is used in place of the toothed wheel without a hydraulic pump mounted.
39295 0
Remove crankshaft toothed wheel (1). Remove lube oil pump Job card W 08-04-05.
39296 0
11/2004
3/12
Crankcase W 03-08-01
Unscrew screws (1) and remove hydraulic pump console with hydraulic pump.
2011
39297 0
Unscrew screw (1) and remove cable plug (2) from engine shutdown. Pull out cable plug (3) from lifting magnet for start volume release. Remove lube oil tray Job card W 08-08-02.
1 2
39298 0
Unscrew screws (arrows) and remove front cover. Check components for visible signs of damage.
39299 0
11/2004
4/12
2011
Install front cover Knock out crankshaft sealing ring (1).
Crankcase W 03-08-01
Note
Do not damage the sealing surface when knocking out. Clean the sealing surfaces on the front cover and crankcase.
39527 0
Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. Fit the crankshaft sealing ring (1) to the assembly sleeve(2).
6
1 2
Note
The sealing lip must face the crankshaft in assembly.
39515 0
Drive in crankshaft sealing ring with assembly tool. Press in assembly tool to stop.
Note
The installation depth of the crankshaft sealing ring is determined by the assembly tool.
33948 1
11/2004
5/12
Crankcase W 03-08-01
Coat sealing surface of the front cover with sealant DEUTZ DW 67.
2011
Note
The connection between the camshaft pin and the centrifugal force regulator must be clean and free of oil. Turn engine 180.
Note
The oil tray sealing surface on the crankcase must face up.
34110 1
Mount the front cover with shaft sealing ring and tighten the screws. Align the front cover flush with the oil tray sealing surface (arrows).
Note
- The sealing lips of the shaft sealing rings (1) must touch the bearing journal all round. - Do not tighten screws.
39450 0
34112 1
11/2004
6/12
2011
Plug the cable plug (2) to the engine shutdown and tighten the screw (1). Plug the cable plug (3) to the lifting magnet for start volume release.
Crankcase W 03-08-01
1 2
39298 0
Clean the sealing surface on the hydraulic pump console and crankcase. Insert new round sealing ring (arrow).
39451 0
39452 0
11/2004
7/12
Crankcase W 03-08-01
Mount the hydraulic pump console and tighten the screws.
2011
Note
Note different screw length: Screw M10 x 75 mm (1) Screws M10 x 90 mm (2)
39668 0
Install lube oil pump Job card W 08-04-05. Renew camshaft sealing ring Job card W 04-03-01.
39297 0
Note
All connections must be clean and oil free.
39453 0
11/2004
8/12
2011
Mount toothed wheel (1) for hydraulic pump.
Crankcase W 03-08-01
Note
- An adapter is used in place of the toothed wheel without a hydraulic pump mounted. - All connections must be clean and oil free.
39454 0
Note
Use new screw.
39455 0
39456 0
11/2004
9/12
Crankcase W 03-08-01
Mount intermediate disc.
2011
Note
The fixing bolts (1) must engage the bores (2).
1
39374 0
Mount holder.
Note
- The fixing bolts (1) must engage the bores (2). - Do not turn the crankshaft.
39375 0
Note
Do not turn the crankshaft.
39293 0
11/2004
10/12
2011
Mount force multiplier with socket.
Crankcase W 03-08-01
Note
Snap in setting bolts (1) in CW position.
39457 0
Turn the ratchet (1) of the force multiplier to the stop (arrow). Set scale dial (2) to "0".
1
39458 0
39459 0
11/2004
11/12
Crankcase W 03-08-01
Hold the force multiplier to counter (arrows), press setting bolts (1) and release force multiplier.
2011
Caution!
!
Remove the force multiplier with socket, holder and intermediate disc.
39669 0
Install camshaft toothed belt wheel Mount camshaft toothed belt wheel (3) and tighten center screw (1) with washer (2).
Note
- There is no washer (2) on the camshaft toothed belt wheel with torsional vibration damper. - All connections must be clean and oil free.
2 1
39243 0
Install toothed belt and clamping roller, fix camshaft toothed belt wheel Job card W 04-04-12(new version) Job card W 04-04-12(old version)
11/2004
12/12
2011
W 03-08-03
Crankcase W 03-08-03
Dismantle and complete front cover (Speed governor with torque adjustment)
Tools
- Commercial tools Depth-measuring appliance - Special tools 100 400 - Meter 100 750 - Measuring device
References
- W 03-08-01
Note
Distinguishing mark for a speed governor with torque adjustment: Adjustment capsule with clamping claw (1) in place of a full load volume stop.
39629 0
Dismantle front cover Remove front cover Job card W 03-08-01. Unscrew screw (1) and remove bleed valve (2).
39261 0
11/2004
1/24
Crankcase W 03-08-03
Unscrew screws (1) and remove lifting magnet (2).
2011
1
39262 0
2
1
39263 0
1
39631 0
11/2004
2/24
2011
Unscrew nuts (1). Remove controller lever shaft with roller lever (2) and adjustment lever (3).
Crankcase W 03-08-03
2
39632 0
Note
Pay attention to number and arrangement.
39633 0
39634 0
11/2004
3/24
Crankcase W 03-08-03
Unscrew nut (1) and remove clamping claw (2). Unscrew idling capsule (3) and remove spring (4).
2011
39637 0
1 2
39635 0
39336 0
11/2004
4/24
2011
For speed governor with minus adjustment Remove locking ring (1) and deflector lever (2).
Crankcase W 03-08-03
39269 0
6
1
39270 0
Remove locking ring (1). Pull out actuating lever (2), remove spring and washer.
2 1
39530 0
11/2004
5/24
Crankcase W 03-08-03
Unhook spring from stop (arrow).
2011
39529 0
Knock out clamping pin (1), remove shutoff lever (2) and disc.
39528 0
Remove guide bush (1) and round sealing ring (2). Pull out shutoff shaft (3).
39056 0
11/2004
6/24
2011
For speed governor with minus adjustment Unscrew nut (1) and remove washer.
Crankcase W 03-08-03
39272 0
Note
Mark the installation position of the eccenter shaft (2) before removing.
39467 0
Pull out eccenter shaft (1). Remove guide bush (2) and round sealing ring (3).
39063 0
11/2004
7/24
Crankcase W 03-08-03
Remove locking bolt (arrow).
2011
Note
Do not damage the sealing surface on the front cover.
33928 1
Note
Do not jam the clamping pin in the cover when knocking out.
39470 0
Insert the speed adjustment lever (1) with shaft, guide bush and round sealing ring. Remove adjustment lever (2).
39273 0
11/2004
8/24
2011
Unscrew lock nut (1) and turn out setting screw for minimum speed (2). Check components for visible signs of damage.
Crankcase W 03-08-03
39274 0
Complete front cover Turn in setting screw for minimum speed (2) and put on lock nut (1).
39274 0
Note
The setting dimension X only serves as a basic setting. A test stand run is necessary for the performance and speed setting. Tighten lock nut (2).
05005
33950 1
11/2004
9/24
Crankcase W 03-08-03
Insert the speed adjustment lever (1) with shaft, guide bush and new round sealing ring.
2011
Note
Oil the speed adjustment shaft lightly.
39469 0
Note
Note the installation position, the hole for hooking in the regulator spring (arrow) must face the outside of the front cover. Press the speed adjustment shaft (2) into the front cover to the stop.
39209 0
Note
The bore in the speed adjustment shaft must match up with the bore in the adjustment lever.
39470 0
11/2004
10/24
2011
Knock in the locking bolt (arrow) to the stop.
Crankcase W 03-08-03
Note
The groove in the speed adjustment shaft must match up with the bore in the front cover.
33960 1
For speed governor with minus adjustment Oil lightly and insert the eccenter shaft (1).
39471 0
Note
The groove in the eccenter shaft must match up with the bore for he clamping pin.
39478 0
11/2004
11/24
Crankcase W 03-08-03
Put on new round sealing ring (1) and guide bush (2).
2011
Note
Oil round sealing ring lightly.
39472 0
Fit washer and tighten nut (1). Position the eccenter shaft at the mark made before removal. Tighten nut (1).
05024
39272 0
Insert shutoff shaft, pre-tension spring (1) and hang into stop (arrow).
Note
- Note installation position. - Oil the shutoff shaft lightly.
39473 0
11/2004
12/24
2011
Put on new round sealing ring (1) and guide bush (2).
Crankcase W 03-08-03
Note
Oil round sealing ring lightly.
39474 0
Press the shutoff shaft into the front cover inlet. Put on washer (1) and shutoff lever (2) with clamping pin.
Note
Note installation position of the shutoff lever.
2 1
39475 0
Note
The bore in the shutoff shaft must match up with the bore in the shutoff lever.
39466 0
11/2004
13/24
Crankcase W 03-08-03
For speed governor with minus adjustment Insert actuating lever (1), spring and washer.
2011
Note
Note installation position of the actuating lever.
39476 0
Note
Pay attention to correct fit of the locking ring in the groove.
39464 0
Tighten lifting magnet for start volume release (1) with new round sealing ring.
05065
39270 0
11/2004
14/24
2011
Remove deflector lever (2) and locking ring (1).
Crankcase W 03-08-03
Note
- Note installation position of the deflector lever. - Pay attention to correct fit of the locking ring in the groove.
39269 0
Note
Do not damage the sealing lip of the shaft sealing ring.
39634 0
Measure and set the parallelism of the roller lever. Place shim discs of at least 0.3 mm on the stud bolts (1).
39633 0
11/2004
15/24
Crankcase W 03-08-03
Insert regulator lever shaft with roller lever (1) and tighten nuts (2).
05021
2011
2 1
Note
Note the installation position of the regulator lever shaft, the side with the long cut-out X must face the opening for the lube oil pump and the shim disc.
X
39277 0
Place shims underneath the contact surface of the roller lever (1) so that the ball bearings do not touch the muff (arrows)
39278 0
Insert meter in measuring bridge and position the stylus with pre-tension on the ball bearing (1). Adjust meter to "0".
39279 0
11/2004
16/24
2011
Move the measuring bridge and position the stylus on the ball bearing (1). Read and note measured value.
Crankcase W 03-08-03
Note
The difference between both measured values is max. 0.05 mm. To achieve the required tolerance shims of max. 0.5 mm may be placed under one stud bolt.
39280 0
Compensate the tolerance by using shim discs (1) of suitable thickness. Repeat the measuring process after setting.
39633 0
Unscrew nuts and remove regulator lever shaft. Push the adjustment lever (1) onto the regulator lever shaft (2).
Note
Note installation position of the adjustment lever.
1
33967 1
11/2004
17/24
Crankcase W 03-08-03
Remove regulator lever shaft with roller lever (2) and adjustment lever (3). Tighten nuts (1).
05021
2011
2
Note
Note installation position of the regulator lever shaft.
39632 0
1
39631 0
33940 1
11/2004
18/24
2011
Pre-assemble the adjustment capsule Turn in the spring pre-tensioner (1) to the stop in the housing (2) with max. 1 Nm. Turn out the spring pre-tensioner 1 + 0.5 turns again. Tighten lock nut (3).
05006
Crankcase W 03-08-03
33941 0
Turn in setting screw (2) to the stop on the pressure capsule (1). Turn out the setting screw 1 turn again. Tighten lock nut (3).
05008
2 3
33942 1
Note
Oil round sealing ring lightly.
39463 0
11/2004
19/24
Crankcase W 03-08-03
Screw in adjustment capsule (1).
2011
39636 0
Measure screw-in depth "X" of the adjustment capsule with depth measuring appliance from the front cover to the housing.
05 06
Note
- If necessary, correct the screw-in depth of the adjustment capsule. - The setting dimension "X" only serves for basic setting, a test stand run is necessary for the exact setting.
33944 1
1 2
39635 0
11/2004
20/24
2011
Fit new round sealing ring (arrow) onto idling.
Crankcase W 03-08-03
Note
Oil round sealing ring lightly.
39477 0
Insert spring (1) and turn in idling capsule (2) flush with the inside edge of the front cover (arrow).
2 1
34002 1
Note
Note installation position of the clamping claw.
05022
2
39264 0
11/2004
21/24
Crankcase W 03-08-03
Mount cover (2) with new gasket and tighten screws (1).
05025
2011
2
1
39263 0
39036 0
1
05041
39262 0
11/2004
22/24
2011
Pull new round sealing ring (1) onto bleed valve (2).
Crankcase W 03-08-03
2 1
39029 0
6
1
Note
The bleed valve must contact the front cover evenly. Tighten screw (1).
2
03060
39261 0
11/2004
23/24
Crankcase W 03-08-03
Notes
2011
11/2004
24/24
2011
W 03-08-03
Crankcase W 03-08-03
Dismantle and complete front cover (Speed governor without torque adjustment)
Tools
- Commercial tools Depth-measuring appliance - Special tools 100 400 - Meter 100 750 - Measuring device
References
- W 03-08-01
Note
Distinguishing mark for a speed governor without torque adjustment: Full load volume stop (arrow) in place of adjustment capsule.
33931 1
Dismantle front cover Remove front cover Job card W 03-08-01. Unscrew screw (1) and remove bleed valve (2).
39261 0
11/2004
1/18
Crankcase W 03-08-03
Unscrew screws (1) and remove lfiting magnet (2).
2011
33914 1
33926 1
33915 1
11/2004
2/18
2011
Unscrew nuts (arrows). Remove controller lever shaft with roller lever (1) and adjustment lever (2).
Crankcase W 03-08-03
33916 1
Note
Pay attention to number and arrangement.
33917 1
33918 1
11/2004
3/18
Crankcase W 03-08-03
Unscrew nut (1) and remove clamping claw (2). Unscrew idling capsule (3) and remove (4) spring.
2011
39637 0
33921 1
33922 1
11/2004
4/18
2011
Remove shutoff lever (1) and guide bush.
Crankcase W 03-08-03
33923 1
Pull out shutoff shaft (1) with spacing bush and spring.
6
1
33924 1
33925 1
11/2004
5/18
Crankcase W 03-08-03
Knock out clamping pin (1).
2011
1
33927 1
Note
Do not damage the sealing surface on the front cover.
33928 1
Pull out the speed adjustment lever (1) with shaft and guide bush, remove the adjustment lever (2).
1 2
33929 1
11/2004
6/18
2011
Remove round sealing ring (arrow).
Crankcase W 03-08-03
33930 1
Loosen lock nut (arrows). Unscrew setting screw for shutoff stop (1), full load stop (2) and minimum speed (3). Check components for visible signs of damage.
1 2
3
39203 0
Complete front cover Screw in setting screw for shutoff stop (1), minimum speed (2) and full load stop (3).
1 3
Note
Renew round sealing ring on full load stop. Screw on lock nuts.
33938 1
11/2004
7/18
Crankcase W 03-08-03
Set setting screw (1) for full load stop to dimension "X".
05 04
2011
2
33939 1
Screw in setting screw (1) for shutoff stop so that the lock nut is flush with the end of the bolt (arrows). Tighten lock nut.
05007
1
33949 1
Note
The setting dimension X only serves as a basic setting. A test stand run is necessary for the performance and speed setting. Tighten lock nut (2).
05005
33950 1
11/2004
8/18
2011
Push the spacer bush (arrow) and spring onto the shutoff shaft.
Crankcase W 03-08-03
33951 1
Note
- Note installation position. - Oil the shutoff shaft lightly.
33952 1
Note
Oil round sealing ring lightly.
33953 1
11/2004
9/18
Crankcase W 03-08-03
Insert guide bush (1).
2011
33954 1
Press the shutoff shaft into the front cover to the stop. Push on shutoff lever with clamping pin.
Note
Note installation position of the shutoff lever.
33955 1
Note
The bore in the shutoff shaft must match up with the bore in the shutoff lever.
33955 1
11/2004
10/18
2011
Insert new round sealing ring (1).
Crankcase W 03-08-03
Note
Oil round sealing ring lightly.
1
33956 1
Insert the speed adjustment lever (1) with shaft and guide bush (2).
Note
- Oil the speed adjustment shaft lightly. - Observe the installation position of the speed adjustment lever.
33957 1
Note
Note the installation position, the hole for hooking in the regulator spring (arrow) must face the outside of the front cover. Press the speed adjustment shaft (2) into the front cover to the stop.
39057 0
11/2004
11/18
Crankcase W 03-08-03
Drive in clamping pin (1) flush with the adjustment lever.
2011
Note
The bore in the speed adjustment shaft must match up with the bore in the adjustment lever.
1
33959 1
Note
The groove in the speed adjustment shaft must match up with the bore in the front cover.
33960 1
Note
Do not damage the sealing lip of the shaft sealing ring.
33962 1
11/2004
12/18
2011
Measure and set the parallelism of the roller lever. Place shim discs of at least 0.3 mm on the stud bolts (1).
Crankcase W 03-08-03
33963 1
Insert regulator lever shaft with roller lever (1) and tighten nuts (2).
05021
6
2 1
Note
Note the installation position of the regulator lever shaft, the side with the long cut-out X must face the opening for the lube oil pump and the shim disc.
X
39277 0
Place shims underneath the contact surface of the roller lever (1) so that the ball bearings do not touch the muff (arrows).
39278 0
11/2004
13/18
Crankcase W 03-08-03
Insert meter in measuring bridge and position the stylus with pre-tension on the ball bearing (1). Adjust meter to "0".
2011
1
33965 1
Move the measuring bridge and position the stylus on the ball bearing (1). Read and note measured value.
Note
The difference between both measured values is max. 0.05 mm. To achieve the required tolerance shims of max. 0.5 mm may be placed under one stud bolt.
1
33966 1
Compensate the tolerance by using shim discs (1) of suitable thickness. Repeat the measuring process after setting.
33963 1
11/2004
14/18
2011
Unscrew nuts and remove regulator lever shaft. Push the adjustment lever (1) onto the regulator lever shaft (2).
Crankcase W 03-08-03
Note
Note installation position of the adjustment lever.
1
33967 1
Insert regulator lever shaft with roller lever and adjustment lever. Tighten nuts.
05021
Note
Note installation position of the regulator lever shaft.
33968 1
33969 1
11/2004
15/18
Crankcase W 03-08-03
Fit new round sealing ring (arrow) onto idling capsule.
2011
Note
Oil round sealing ring lightly.
39477 0
Insert spring (1) and turn in idling capsule (2) flush with the inside edge of the front cover (arrow).
2 1
34002 1
Note
Note installation position of the clamping claw.
05022
2
39264 0
11/2004
16/18
2011
Mount cover (1) with new gasket and tighten screws (2).
05025
Crankcase W 03-08-03
33970 1
6
1
33971 1
Note
Note installation position of the lifting magnet.
05041
33972 1
11/2004
17/18
Crankcase W 03-08-03
Pull new round sealing ring (1) onto bleed valve.
2011
2 1
39029 0
Note
The bleed valve must contact the front cover evenly. Tighten screw.
03060
33974 1
11/2004
18/18
2011
W 03-09-01
Crankcase W 03-09-01
References
- W 03-09-04 - W 08-04-07
Auxiliary material
- DEUTZ DW 67
Remove rear cover (flywheel side) Remove connection housing Job card W 03-09-04. Remove oil tray Job card W 08-04-07. Unscrew screws (arrows) and remove rear cover (1).
6
1
39031 0
Renew crankshaft sealing ring Knock out crankshaft sealing ring (1).
Note
- Do not damage the sealing surface when knocking out. Check the rear cover visually, renew if necessary.
39512 0
11/2004
1/4
Crankcase W 03-09-01
Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. Fit the crankshaft sealing ring (1) to the assembly sleeve (2).
2011
2 1
Note
The sealing lip must face the crankshaft in assembly.
39510 0
Note
Installation depth X = approx. 2.5 mm of the crankshaft sealing ring.
X
39352 0
Note
- Note installation depth.
33828 1
11/2004
2/4
2011
Install rear cover (flywheel side) Clean the sealing surface on the rear cover and crankcase. Apply sealant DEUTZ DW 67 to rear cover.
Crankcase W 03-09-01
34100 1
Mount the rear cover with crankshaft sealing ring and tighten the screws.
Note
- The sealing lip of the crankshaft sealing ring must be touching the crankshaft journal all round. - Do not tighten screws. Align the rear cover to the sealing surface of the oil tray (arrows).
39034 0
2 8
Install oil tray Job card W 08-04-07. Install connection housing Job card W 03-09-04.
7 3 4 5 1
39037 0
11/2004
3/4
Crankcase W 03-09-01
Notes
2011
11/2004
4/4
2011
W 03-09-04
Crankcase W 03-09-04
References
- W 00-05-01 - W 12-06-01
Remove connection housing Mount engine on engine assembly stand Job card W 00-05-01. Remove flywheel Job card W 12-06-01. Unscrew screws (1) and remove engine mounting (2).
39041 0
39046 0
11/2004
1/4
Crankcase W 03-09-04
Install connection housing Clean contact surfaces on connection housing and crankcase.
2011
39048 1
Note
Make sure the clamping sleeves (arrows) are in place. Knock clamping sleeves into the crankcase to the stop. Mount the connection housing and center over the clamping sleeves.
39049 0
39053 0
11/2004
2/4
2011
Mount engine bearing (2) and tighten screws (1).
00003
Crankcase W 03-09-04
Note
Note installation position. Install flywheel. Job card W 12-06-01. Disassemble engine from engine assembly stand Job card W 00-05-01
39041 0
11/2004
3/4
Crankcase W 03-09-04
Notes
2011
11/2004
4/4
2011
W 03-11-01
Crankcase W 03-11-01
References
- W 01-02-02 - W 02-04-01 - W 07-04-01(Motorpal) - W 07-04-01(Bosch) - W 07-11-01
Remove camshaft Remove crankshaft Job card W 02-04-01. Remove toggle lever and toggle lever blocks Job card W 01-02-02. Remove injection pumps Job card W 07-04-01 (Motorpal) Job card W 07-04-01 (Bosch) Remove fuel pump Job card W 07-11-01.
39199 0
Unscrew screw (1) and remove startup disc (2). Unscrew setting bolts (3).
3
39302 0
11/2004
1/10
Crankcase W 03-11-01
Press in all tappets. Pull out camshaft (1) carefully to the flywheel side.
2011
39303 0
Check the camshaft bearing. Prepare internal measuring device Mount probe bolt for the appropriate measuring range in the internal measuring device. Mount meter with approx. 1 mm pre-tension in the internal measuring device. Set micrometer gauge to 54 mm. Balance the internal measuring device between the test surfaces of the micrometer gauge and set the meter to the reversal point of the pointer to "0".
34768 1
Note
Schematic representation for measuring the camshaft bearing at the points "a" and "b" in the levels "1" and "2".
37239 0
11/2004
2/10
2011
Measure camshaft bearing with internal measuring device. Insert internal measuring device in the camshaft bearing. Balance the internal measuring device respectively at the given measuring points and read off the measured value at the reversal point of the pointer.
Crankcase W 03-11-01
Note
- Measuring points, see schematic diagram. - If the wear limit is reached, the bearing has to be changed.
03 13 03 14
39304 0
Note
Put down the components in the order of installation, note order of cylinders.
39305 0
Remove outer camshaft bearing Insert extraction bush (1) in outer camshaft bearing.
39306 0
11/2004
3/10
Crankcase W 03-11-01
Push in spindle, push on holder (1) and insert in inside camshaft bearing.
2011
Note
Make sure that the holder is evenly in contact with the crankcase. Fit washer and nut.
39307 0
Press out outer camshaft bearing. Dismantle assembly tool and remove camshaft bearing.
39308 0
Remove inner camshaft bearing Insert extraction bush (1) in inner camshaft bearings. Insert spindle and fit washer and nut.
Note
Align counterbearing in the center of the bearing bore (arrow).
39309 0
11/2004
4/10
2011
Pull out inner camshaft bearing. Dismantle assembly tool and remove camshaft bearing.
Crankcase W 03-11-01
39310 0
Note
Schematic for installation direction of the joint in the camshaft bearing.
39311 0
Note
Schematic for the installation depth of the camshaft bearing.
Number of cylinders 2-cylinder 3-cylinder B = opposite side to flywheel 0.5 0.3 mm 117.1 0.3 mm 0.5 0.3 mm 117.1 0.3 mm 0.5 0.3 mm 117.1 0.3 mm 228.1 0.3 mm
A = flywheel side 2.5 0.3 mm 2.5 0.3 mm 118.9 0.3 mm 2.5 0.3 mm 118.9 0.3 mm
4-cylinder
33794 1
11/2004
5/10
Crankcase W 03-11-01
Install inner camshaft bearing Mount inner camshaft bearing.
2011
Note
- Note position of joint (1), see schematic diagram. - Check that the oil bores (arrows) in the camshaft bearing and the crankcase match up.
39312 0
Insert extraction bush (1) in the inner camshaft bearing. Insert spindle and fit washer and nut.
Note
- Do not change the installation position of the camshaft bearing. - Counterbearing centered to bearing bore.
39313 0
Pull in camshaft bearing until the extraction socket is almost flush with the crankcase (arrow). Loosen assembly tool. Check that the lube oil bores match up.
Note
If the lube oil bores do not match up, the camshaft bearing must be mounted again.
39314 0
11/2004
6/10
2011
Measure the installation depth of the camshaft bearing with the depth measuring appliance from the crankcase joint to the camshaft bearing.
Crankcase W 03-11-01
Note
- Correct the installation depth of the camshaft bearing if necessary. - Installation depth, see schematic diagram. Remove the assembly tool.
39315 0
6
2
Note
- Note position of joint (1), see schematic diagram. - Check that the oil bores (2) in the camshaft bearing and the crankcase match up. - In the camshaft bearing on the flywheel side, the bores (3) for the setting bolts must match up with the camshaft lock.
39316 0
Insert counterbearing (1) in inner camshaft bearing. Insert spindle and fit washer and nut. Insert extraction bus in outer camshaft bearing.
Note
- Do not change the installation position of the camshaft bearing. - Make sure that the counterbearing is evenly in contact with the crankcase.
39307 0
11/2004
7/10
Crankcase W 03-11-01
Pull in the camshaft bearing. Loosen assembly tool. Check that the lube oil bores match up.
2011
Note
If the lube oil bores do not match up, the camshaft bearing must be mounted again.
39317 0
Measure the installation depth of the camshaft bearing with the depth measuring appliance from the crankcase joint to the camshaft bearing.
Note
- Correct the installation depth of the camshaft bearing if necessary. - Installation depth, see schematic diagram. Remove the assembly tool.
39318 0
Note
Note assignment.
39305 0
11/2004
8/10
2011
Install camshaft Oil camshaft bearing and camshaft journal lightly.
Crankcase W 03-11-01
Note
The connecting surface (arrow) with the muff of the measuring mechanism must be clean and oil free.
39252 0
Note
Check that the bores (1) in the camshaft and the crankcase match up.
39319 0
Note
The lubricating groove (2) of the startup disc must face the crankcase.
2
39320 0
11/2004
9/10
Crankcase W 03-11-01
Turn in the setting bolt (1), for locking the camshaft, to the stop in the crankcase. Tighten screw.
04002
2011
39321 0
Install crankshaft Job card W 02-04-01. Install toggle lever and toggle lever blocks Job card W 01-02-02. Install fuel pump Job card W 07-11-01. Install injection pumps. Job card W 07-04-01(Motorpal) Job card W 07-04-01(Bosch)
39199 0
11/2004
10/10
2011
W 04-04-11
References
- W 04-04-12 (old version) - W 04-04-12 (new version)
Caution!
It is not permissible to retighten a toothed belt which has already been in operation and to set the engine control times.
Check engine control times Lock camshaft. Unscrew cap (1) and remove sealing ring.
39670 0
Insert setting bolt (1) in the bore (2) to lock the camshaft.
39671 0
11/2004
1/4
2011
39672 0
39186 0
39187 0
11/2004
2/4
2011
Tighten center screw with the torque wrench in engine direction of rotation with 40 Nm. Carefully relieve pressure on the torque wrench.
Note
Do not turn the crankshaft any more.
34143 1
Turn in the setting bolt (1) to the crankshaft lock until it is lightly touching the crankshaft.
Note
Do not turn the crankshaft when screwing in the setting bolt. Make help marks (arrow) on the crankcase and setting bolt.
39517 0
The engine control times are set correctly when the setting bolt can be turned another 0.75 to 2.25 turns up to the stop in the crankcase.
Note
If the screw-in depth "X" deviates from the specification, the toothed belt and the clamping roller must be changed. Renew toothed belt and clamping roller Job card W 04-04-12(old version) Job card W 04-04-12(new version) Unscrew the setting bolts for camshaft and crankshaft locking.
39543 0
11/2004
3/4
2011
39670 0
39187 0
11/2004
4/4
2011
W 04-04-12
Renew toothed belt and clamping roller (old version of the clamping roller)
Tools
- Commercial tools 8189 - Torx tool kit 9120 - Special bit, 70 mm long 9122 - Special bit, 25 mm long - Special tools 100 700 - Setting bolt 144 130 - Holder
!
References
- W 12-02-01 (FL, BFL engines) - W 12-02-01 (FM, BFM engines) - W 12-08-03
Caution!
The toothed belt and the clamping roller must be renewed after every disassembly regardless of their time in operation.
Note
Distinguishing features of the old version of the clamping roller: - Pointer and notch (1) serve to set and check the toothed belt tension. - The clamping roller is locked by a guide fork (2) on the front cover.
2
39258 0
Renew toothed belt and clamping roller Remove V-belt Job card W 12-02-01 (FL, BFL engines) Job card W 12-02-01 (FM, BFM engines) In FM, BFM engines If available, unscrew screws (1) and remove fan.
39625 0
11/2004
1/16
2011
2 1
39461 0
Note
Hold at the center screw.
1
39354 0
Remove centrifugal disc (1). Remove toothed belt and clamping roller of the hydraulic pump Job card W 12-08-03.
39355 0
11/2004
2/16
2011
In FL, BFL engines Unscrew screws (1) and remove V-belt clamping roller (2).
39356 0
Note
Use a special bit, 70 mm long. Unscrew screws (2) and remove protective cover (1).
1 3
39357 0
1
39358 0
11/2004
3/16
2011
39670 0
Insert setting bolt (1) in the bore (2) to lock the camshaft.
39671 0
Hold the setting bolt lightly and turn the crankshaft in the direction of rotation of the engine (clockwise) until the setting bolt engages the bore of the camshaft.
39672 0
11/2004
4/16
2011
Screw setting bolt (1) into the crankcase to the stop.
39186 0
Lock the crankshaft Unscrew cap (1) and remove sealing ring.
39187 0
Insert setting bolt (1) in the bore (2) to lock the crankshaft.
1
39516 0
11/2004
5/16
2011
Note
The cylinder at the front cover is now in the ignition UT.
39188 0
Unscrew screw (1) and remove clamping roller (2). Remove toothed belt (3).
1 2
34054 1
Loosen camshaft toothed belt wheel Mount holder (1) and loosen center screw (2).
Note
Do not turn the camshaft.
39359 0
11/2004
6/16
2011
Install toothed belt and clamping roller Tighten the center screw (1) hand tight.
Note
- To guarantee the length compensation of the toothed belt, the camshaft toothed belt wheel must still be turnable. - Use new center screw.
39360 0
Turn the crankshaft carefully in the direction of rotation of the engine (clockwise) until it touches the setting bolts.
39130 0
Note
Note the running direction of the toothed belt, the arrows (1) must point in the direction of rotation of the engine (arrow).
39361 0
11/2004
7/16
2011
Note
When installing a hydraulic pump, watch out for different clamping rollers. Width of clamping roller for: - Camshaft drive 30 mm - Hydraulic pump drive 35 mm Screw in screw (3).
39362 0
Position setting eccenter (arrow) in 6:00 h position. Press the clamping roller against the toothed belt and pre-tighten the screw (1).
04052
39363 0
Align the toothed belt so that there is an even distance between the cover and toothed belt of 8 to 9 mm.
34132 1
11/2004
8/16
2011
Tighten the draw side (1) of the toothed belt by turning the camshaft toothed belt wheel in the direction of the arrow (counterclockwise).
Note
- Turn the camshaft toothed wheel by hand, not by the center screw. - The crankshaft must be held against the stop whilst setting the toothed belt.
39364 0
34133 1
Turn the setting eccenter in the direction of the arrow (counterclockwise) until the pointer of the clamping roller is in line with the notch (1).
Note
Turn the setting eccenter at the hexagon socket. Tighten screw.
04052
34134 1
11/2004
9/16
2011
Note
- Hold the toothed belt wheel. - Hold the crankshaft against the stop.
34135 1
Check the toothed belt tension Unscrew the setting bolts for camshaft and crankshaft locking. Make help marks on the camshaft toothed belt wheel and the screw opposite (arrow).
34138 1
Turn the crankshaft 2 turns in the direction of rotation of the engine (clockwise) until the help marks (1) are in line.
34139 1
11/2004
10/16
2011
Note
- The pointer of the clamping roller must be in line with the notch (1). - If the marks are not in line, the toothed belt tension must be corrected.
34140 1
Turn the setting eccenter in the direction of the arrow (counterclockwise) until the pointer of the clamping roller is in line with the notch (1). Tighten screw.
04052
34134 1
Check engine control times Lock camshaft. Insert setting bolt (1) for the camshaft lock in the bore and hold lightly. Turn the crankshaft in the direction of rotation of the engine (clockwise) until the setting bolt engages the bore of the camshaft. Turn the setting bolt into the crankcase to the stop.
39186 0
11/2004
11/16
2011
Note
Do not turn the crankshaft any more.
34143 1
Turn in the setting bolt (1) for the crankshaft lock until it is lightly touching the crankshaft.
Note
Do not turn the crankshaft when screwing in the setting bolt. Make help marks (arrow) on the crankcase and setting bolt.
39517 0
The engine control times are set correctly when the setting bolt can be turned another 0.75 to 2.25 turns up to the stop in the crankcase.
Note
If the screw-in depth "X" deviates from the specification, the toothed belt and the clamping roller must be changed. Unscrew the setting bolts for camshaft and crankshaft locking.
39543 0
11/2004
12/16
2011
Tighten locking screw (1) with new CU sealing ring.
03003
39670 0
39187 0
Inspect the protective covers visually, renew the sealing profile if necessary.
34229 1
11/2004
13/16
2011
Note
Pay attention to the correct fitting of the protective cover.
04053
1
39358 0
Mount protective cover (3) and tighten screws (2) . Screw in locking screw (1).
Note
Use a special bit, 70 mm long. Tighten screws.
04053
1 3
39357 0
Install toothed belt and clamping roller of the hydraulic pump Job card W 12-08-03. Mount centrifugal disc (1).
Note
The hollow throat must face the adapter.
1
39598 0
11/2004
14/16
2011
Fit V-belt pulley (1) and tighten screws (2) alternately.
Note
Hold at the center screw.
1 2
12031
39599 0
In FM, BFM engines If available, mount V-belt pulley and flange hub (1). Tighten (2) screws alternately.
12031
2 1
2
39462 0
39624 0
11/2004
15/16
2011
39356 0
11/2004
16/16
2011
W 04-04-12
Renew toothed belt and clamping roller (new version of the clamping roller)
Tools
- Commercial tools 8189 - Torx tool kit 9120 - Special bit, 70 mm long 9122 - Special bit, 25 mm long - Special tools 100 700 - Setting bolt 144 130 - Holder
!
References
- W 12-02-01 (FL, BFL engines) - W 12-02-01 (FM, BFM engines) - W 12-08-03
Caution!
The toothed belt and the clamping roller must be renewed after every disassembly regardless of their time in operation.
Note
Distinguishing features of the new version of the clamping roller: - The bores (arrows) serve for setting and inspecting the toothed belt tension. - The clamping roller has no lock on the front cover.
39600 0
Renew toothed belt and clamping roller Remove V-belt Job card W 12-02-01 (FL, BFL engines) Job card W 12-02-01 (FM, BFM engines) In FM, BFM engines If available, unscrew screws (1) and remove fan.
39625 0
11/2004
1/16
2011
2 1
39461 0
Note
Hold at the center screw.
1
39354 0
Remove centrifugal disc (1). Remove toothed belt and clamping roller of the hydraulic pump Job card W 12-08-03.
39355 0
11/2004
2/16
2011
In FL, BFL engines Unscrew screws (1) and remove V-belt clamping roller (2).
39356 0
Note
Use a special bit, 70 mm long. Unscrew screws (2) and remove protective cover (1).
1 3
39357 0
1
39358 0
11/2004
3/16
2011
39670 0
Insert setting bolt (1) in the bore (2) to lock the camshaft.
39671 0
Hold the setting bolt lightly and turn the crankshaft in the direction of rotation of the engine (clockwise) until the setting bolt engages the bore of the camshaft.
39672 0
11/2004
4/16
2011
Screw setting bolts (1) into the crankcase to the stop.
39186 0
Lock the crankshaft Unscrew cap (1) and remove sealing ring.
39187 0
Insert setting bolt (1) in the bore (2) to lock the crankshaft.
1
39516 0
11/2004
5/16
2011
Note
The cylinder at the front cover is now in the ignition UT.
39188 0
Unscrew screw (1) and remove clamping roller (2). Remove toothed belt (3).
2
39602 0
Loosen camshaft toothed belt wheel (without torsional vibration damper) Mount holder (1) and loosen center screw (2).
Note
Do not turn the camshaft.
39359 0
11/2004
6/16
2011
Loosen camshaft toothed belt wheel (with torsional vibration damper)
Note
For camshaft toothed belt wheels with torsional vibration dampers, the hexagon is no longer on the toothed belt wheel (1) but directly on the camshaft toothed belt wheel (2).
39513 0
Hold camshaft toothed belt wheel and loosen the center screw (1).
6
1
Note
Do not turn the camshaft.
39673 0
Install toothed belt and clamping roller Tighten the center screw (1) hand tight.
Note
- To guarantee the length compensation of the toothed belt, the camshaft toothed belt wheel must still be turnable. - Use new center screw.
39360 0
11/2004
7/16
2011
39130 0
Note
Note the running direction of the toothed belt, the arrows (1) must point in the direction of rotation of the engine (arrow).
39361 0
Mount new clamping roller (1) and position setting eccenter (arrow) at 6.00 h position.
Note
When installing a hydraulic pump, watch out for different clamping rollers. Width of clamping roller for: - Camshaft drive 30 mm - Hydraulic pump drive 35 mm Screw in screw (2).
39603 0
11/2004
8/16
2011
Press the clamping roller against the toothed belt and pre-tighten the screw.
04052
39604 0
Align the toothed belt so that there is an even distance between the cover and the toothed belt of 8 to 9 mm.
34132 1
Tighten the draw side (1) of the toothed belt by turning the camshaft toothed belt wheel in the direction of the arrow (clockwise).
Note
- Turn the camshaft toothed wheel by hand, not by the center screw. - The crankshaft must be held against the stop whilst setting the toothed belt.
39364 0
11/2004
9/16
2011
Note
Turn the setting eccenter at the hexagon socket. Tighten screw (2).
04052
39605 0
Fix the camshaft toothed belt wheel (without torsional vibration damper) Mount holder (1) and pre-tighten center screw (2). Tighten center screw (2).
2 1
Note
- Hold the toothed belt wheel. - Hold the crankshaft against the stop.
04001
39606 0
Fix the camshaft toothed belt wheel (with torsional vibration damper) Pre-tighten (1) and tighten center screw.
Note
- Hold the camshaft toothed belt wheel - Hold the crankshaft against the stop.
04001
39674 0
11/2004
10/16
2011
Check the toothed belt tension Unscrew the setting bolts for camshaft and crankshaft locking. Make help marks on the camshaft toothed belt wheel and insert the screw opposite (1). Turn the crankshaft 2 turns in the direction of rotation of the engine (clockwise) until the help marks are in line.
39607 0
Note
- The bores (1) in the setting eccenter must be in line. - If the marks are not in line, the toothed belt tension must be corrected.
39608 0
Correct the toothed belt tension Loosen screw (2) and re-tighten.
04052
Turn setting eccenter in direction of arrow (counterclockwise) until the bores (1) in the setting eccenter are in line. Tighten screw (2).
2
04052
39605 0
11/2004
11/16
2011
39186 0
Tighten center screw with the torque wrench in engine direction of rotation with 40 Nm. Carefully relieve pressure on the torque wrench.
Note
Do not turn the crankshaft any more.
39609 0
Turn in the setting bolt (1) to the crankshaft lock until it is lightly touching the crankshaft.
Note
Do not turn the crankshaft when screwing in the setting bolt. Make help marks (arrow) on the crankcase and setting bolt.
39517 0
11/2004
12/16
2011
The engine control times are set correctly when the setting bolt can be turned another 0.75 to 2.25 turns up to the stop in the crankcase.
Note
If the screw-in depth (X) deviates from the specification, the toothed belt and the clamping roller must be changed. Unscrew the setting bolts for camshaft and crankshaft locking.
39543 0
39670 0
39187 0
11/2004
13/16
2011
34229 1
Note
Pay attention to the correct fitting of the protective cover.
04053
1
39358 0
Mount protective cover (3) and tighten screws (2). Screw in locking screw (1).
Note
Use a special bit, 70 mm long. Tighten screws.
2
04053
1 3
39357 0
11/2004
14/16
2011
Install toothed belt and clamping roller of the hydraulic pump Job card W 12-08-03. Mount centrifugal disc (1).
Note
The hollow throat must face the adapter.
1
39598 0
6
1 2
Note
Hold at the center screw.
12031
39599 0
In FM, BFM engines (as an overview) If available, mount the V-belt pulley and flange hub (1). Tighten (2) screws alternately.
12031
2 1
2
39462 0
11/2004
15/16
2011
39624 0
In FL, BFL engines Fit V-belt clamping roller (2) and tighten screws (1). Install V-belt Job card W 12-02-01 (FL, BFL engines) Job card W 12-02-01 (FM, BFM engines)
39356 0
11/2004
16/16
2011
W 04-05-05
References
- W 01-02-02 - W 03-09-01 - W 04-04-12 (old version) - W 04-04-12 (new version) - W 07-04-01 (Motorpal) - W 07-04-01 (Bosch) - W 07-11-01
Remove camshaft Remove toothed belt and clamping roller and loosen camshaft toothed belt wheel Job card W 04-04-12 (old version) Job card W 04-04-12 (new version) Unscrew center screw (1) with washer (2) and remove the camshaft toothed belt wheel (3).
2 1
Note
There is no washer (2) on the camshaft toothed belt wheel with torsional vibration damper.
39243 0
Remove toggle lever and toggle lever blocks Job card W 01-02-02. Remove injection pumps Job card W 07-04-01 (Motorpal) Job card W 07-04-01 (Bosch) Remove fuel pump Job card W 07-11-01. Remove rear cover (flywheel side) Job card W 03-09-01.
39245 0
11/2004
1/6
2011
39246 0
Press in all tappets. Pull out camshaft (1) carefully to the flywheel side.
39242 0
Note
Put down the components in the order of installation, note order of cylinders. Check the tappets for visible signs of wear.
39247 0
11/2004
2/6
2011
Install tappets Oil all tappets (arrow) lightly with engine oil and insert.
Note
Note assignment.
39247 0
Install camshaft Oil camshaft bearing and camshaft journal lightly with engine oil.
Note
The connecting surface (arrow) with the muff of the measuring mechanism must be clean and oil free.
39252 0
Note
- The muff of the measuring mechanism must engage the front camshaft journal. - Check that the bores (1) in the camshaft and the crankcase match up.
39253 0
11/2004
3/6
2011
Note
The lubricating groove (2) of the startup disc must face the crankcase.
1 2
39254 0
Screw setting bolts (1) into the crankcase to the stop. Tighten screw.
04002
39255 0
Mount camshaft toothed belt wheel (3) and tighten new center screw (1) with washer (2).
Note
- There is no washer (2) on the camshaft toothed belt wheel with torsional vibration damper. - All connections must be clean and oil free. Install toothed belt and clamping roller, fix camshaft toothed belt wheel Job card W 04-04-12 (old version) Job card W 04-04-12 (new version)
2 1
39243 0
11/2004
4/6
2011
Install toggle lever and toggle lever blocks Job card W 01-02-02. Install injection pumps. Job card W 07-04-01 (Motorpal) Job card W 07-04-01 (Bosch) Install fuel pump Job card W 07-11-01. Install rear cover (flywheel side) Job card W 03-09-01.
39256 0
11/2004
5/6
2011
11/2004
6/6
2011
W 04-05-06
Check camshaft
Tools
- Commercial tools
References
- W 04-05-05
Check camshaft Remove camshaft Job card W 04-05-05. Visually inspect cam and bearing pin for wear, renew camshaft if necessary. Install camshaft Job card W 04-05-05.
39058 0
11/2004
1/2
2011
11/2004
2/2
2011
W 05-07-01
Remove speed governor Pull cable plug (1) out of speed governor (2). Unscrew screw (3) and remove speed governor.
1 3
36789 1
Install speed governor Fit new round sealing ring (arrow) onto speed governor.
36790 1
11/2004
1/2
2011
1 3
36789 1
11/2004
2/2
2011
W 06-01-05
References
- W 06-06-04
Auxiliary material
- DEUTZ S1
39071 0
Remove exhaust manifold Unscrew screws (arrows), remove exhaust manifold (1) and gaskets. Check components for visible signs of damage.
39222 0
11/2004
1/2
2011
Note
Note installation position of the gaskets (1).
1
39223 0
Note
Coat screws with assembly aid DEUTZ S1. Tighten screws alternately from the center outwards.
06001
39224 0
39071 0
11/2004
2/2
2011
W 06-06-04
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Auxiliary material
- DEUTZ S1
Remove turbocharger If available, remove the bleed pipe (1) and reducer (2). Unscrew screws (3). Loosen pipe clip (4), remove reducer with bleed pipe.
3 1 3
4
39394 0
39395 0
11/2004
1/6
2011
2 1
39396 0
Unscrew hollow screws (1), remove oil pressure line (2) and sealing rings.
1
39397 0
Unscrew screws (1), remove oil return pipe flange support (2) and gasket.
39398 0
11/2004
2/6
2011
Loosen pipe clip (1) with clamping pliers.
39376 0
Unscrew nuts (1), remove turbocharger (2) and gasket. Check components for visible signs of damage.
6
1
39377 0
Install turbocharger Clean the sealing surface of the turbocharger and exhaust manifold. Mount turbocharger (2) with new gasket and tighten nuts (1).
Note
Coat pin bolts with assembly aid DEUTZ S1.
06020
39377 0
11/2004
3/6
2011
39376 0
Clean the sealing surface of the turbocharger and oil return pipe flange support. Mount oil return pipe flange support (1) with new gasket and tighten screws (2).
08044
39627 0
Pull new round sealing ring (arrow) onto oil return pipe flange support.
39399 0
11/2004
4/6
2011
Mount oil pressure line (2), tighten hollow screws (1) with new CU sealing rings.
2
08042
1
39397 0
Fit new round sealing ring (arrow) onto oil return pipe.
39378 0
Push oil return pipe (1) onto oil return pipe flange support (2) and insert in crankcase.
Note
Oil round sealing rings lightly.
2 1
39396 0
11/2004
5/6
2011
39395 0
Clean sealing surface on bleed pipe and cylinder head. If available, install the bleed pipe (1) and reducer (2). Mount reducer with bleed pipe and new gasket, tighten screws (3).
03060
3 1 3
2
03060
4
39394 0
11/2004
6/6
2011
W 06-07-03
References
- W 06-01-05
Remove air intake pipe Remove exhaust manifold Job card W 06-01-05. Unscrew screws (arrows), remove air intake pipe and gaskets.
39059 0
Install air intake pipe Clean sealing surfaces on air intake pipe and cylinder head.
Note
Note installation position of the gaskets (1).
39064 0
11/2004
1/2
2011
39066 0
11/2004
2/2
2011
W 07-02-06
Crankcase W 07-02-06
References
- W 03-08-01 - W 03-09-04 - W 07-04-01 (Motorpal) - W 07-04-01 (Bosch) - W 07-08-02 - W 08-11-12 - W 09-11-01 - W 13-02-03
Auxiliary material
- DEUTZ DW 72
Remove control linkage Remove front cover Job card W 03-08-01. Remove injection pumps Job card W 07-04-01 (Motorpal) Job card W 07-04-01 (Bosch) Remove connection housing Job card W 03-09-04.
39069 0
In FL, BFL engines Remove cooling blower Job card W 09-11-01. In FM, BFM engines Remove generator Job card W 13-02-03. In BFL, BFM engines Remove charging pressure dependent full load stop Job card W 07-08-02.
39069 0
11/2004
1/12
Crankcase W 07-02-06
Knock out cylindrical pin (1).
2011
39072 0
39073 0
Remove guide bush (opposite side to flywheel) Insert assembly pin (1) in guide bush (2).
39074 0
11/2004
2/12
2011
Knock out guide bush.
Crankcase W 07-02-06
39075 0
Install guide bush (opposite side to flywheel) Unscrew locking screw (1).
39076 0
Push spacer bush (1) onto assembly pin (2). Insert assembly pin in the centering (3).
Note
The guide pin (arrow) must engage in the groove (4).
2 1
39077 0
11/2004
3/12
Crankcase W 07-02-06
Push guide bush (1) onto assembly pin.
2011
Note
The chamfer (arrow) must face the crankcase in assembly.
39078 0
Note
- The crankcase contact surface must be clean. - The fixing bolt (1) must engage the bore (2).
2 1
39079 0
Tighten screw (1). Knock in the guide sleeve until the assembly pin touches the spacer bush (arrow). Remove centering with assembly pin.
39082 0
11/2004
4/12
2011
Tighten new locking screw.
Crankcase W 07-02-06
Note
The threaded bore for the locking screw must be free from oil, corrosion and dirt and be dry.
03007
39084 0
Remove oil rise pipe Unscrew locking screw (1). Remove oil thermostat Job card W 08-11-12.
39087 0
39088 0
11/2004
5/12
Crankcase W 07-02-06
Drill oil rise pipe (1) with a 5.5 mm drill on one side.
2011
Note
- Coat the drill with grease so that no drill chips fall into the crankcase. - Remove all drill chips.
39089 0
Insert extraction tool (1) in the oil rise pipe until the bolt (2) snaps into the bore (arrow).
39093 0
39095 0
11/2004
6/12
2011
Pull the oil rise pipe out of the lower press fit (arrow).
Crankcase W 07-02-06
Note
Do not pull out the oil rise pipe completely.
39097 0
39098 0
Remove guide bush (flywheel side) Insert assembly pin (1) in guide bush (2).
2 1
39099 0
11/2004
7/12
Crankcase W 07-02-06
Knock out guide bush.
2011
39204 0
Install guide bush (flywheel side) Insert assembly pin (1) in centering (2).
Note
The guide pin (arrow) must engage in the groove (3).
2 1
3
39205 0
Note
The chamfer (arrow) must face the crankcase in assembly.
39226 0
11/2004
8/12
2011
Insert assembly pin with guide bush.
Crankcase W 07-02-06
Note
The crankcase contact surface must be clean.
39227 0
Mount centering on crankcase and tighten screw (1). Knock in the guide sleeve until the assembly pin touches the centering (arrow). Remove centering with assembly pin.
6
1
39228 0
Install oil rise pipe Insert new oil rise pipe (1).
Note
The chamfer (arrow) must face the crankcase in assembly.
39231 0
11/2004
9/12
Crankcase W 07-02-06
Knock in the oil rise pipe until the assembly pin (1) touches the crankcase (arrow).
2011
39232 0
33816 1
Knock in cap flush with crankcase. Install oil thermostat Job card W 08-11-12.
39233 0
11/2004
10/12
2011
Tighten new locking screw.
Crankcase W 07-02-06
Note
The threaded bore for the locking screw must be free from oil, corrosion and dirt and be dry.
03007
39235 0
Install control linkage Insert control linkage with spring in the guide bushes.
Note
- Note installation position, the latch (1) must face the oil filling nozzle (2). - Pay attention to easy action of the control linkage.
39236 0
Press together spring and insert cylindrical pin (1) in the bore (2).
Note
- The cylindrical pin must engage in the recess (arrow) for the control path limit. - Make sure that the spring touches the cylindrical pin (3).
3 1
39237 0
11/2004
11/12
Crankcase W 07-02-06
Drive in the cylindrical pin flush with the crankcase. Install connection housing Job card W 03-09-04. Install front cover Job card W 03-08-01. Install injection pumps. Job card W 07-04-01 (Motorpal) Job card W 07-04-01 (Bosch) In BFL, BFM engines Install charging pressure dependent full load stop Job card W 07-08-02.
2011
39238 0
In FM, BFM engines Install generator Job card W 13-02-03. In FL, BFL engines Install cooling blower Job card W 09-11-01.
11/2004
12/12
2011
W 07-02-07
Remove lifting magnet for start volume release Pull cable plug (1) out of lifting magnet (2).
2 1
39662 0
Unscrew lifting magnet (1) with pliers insert and remove sealing ring.
Note
Note clamping direction of the pliers insert. Check components for visible signs of damage.
39663 0
11/2004
1/2
2011
1
05065
39664 0
2 1
39662 0
11/2004
2/2
2011
W 07-03-01
Note
- Cleanliness is extremely important when working on the injection equipment. - Bending the injection lines is not permissible. Small tears may occur which lead to a reduction in the fatigue strength. - Collect drained operating materials in suitable vessels and dispose of according to regulations.
References
- W 08-08-02
Caution!
!
Observe the safety regulations and and national specifications for handling fuels.
Remove injection lines In FL, BFL engines Remove oil cooler Job card W 08-08-02. Unscrew screw (1).
1
39481 0
39468 0
11/2004
1/4
2011
Note
- Put down the components in the order of installation, note order of cylinders. - Seal openings on the injection valve and the injection pump.
39482 0
Install injection lines Mount injection line on injection pump and injection valves and tighten union nuts (1).
Note
Mount the injection lines without tension. Tighten the union nuts of the injection line on the injection pump and injection valve.
07003
39482 0
In FL, BFL engines Mount air feed (2) and tighten screws (1).
39468 0
11/2004
2/4
2011
Tighten screw (1).
1
39481 1
11/2004
3/4
2011
11/2004
4/4
2011
W 07-04-01
References
- W 07-03-01 - W 07-06-04 - W 07-10-06
Note
Distinguishing features for the Bosch injection pump: - Short pump housing.
39300 0
Remove injection pump Remove injection lines Job card W 07-03-01. Remove fuel supply line Job card W 07-10-06. Unscrew nuts (1), remove injection pump (arrows) and compensation gaskets.
1 1
Note
- Loosen nuts evenly to avoid jamming the injection pump. - Put down the components in the order of installation, note order of cylinders.
34043 2
11/2004
1/8
2011
Note
- Put down the components in the order of installation, note order of cylinders. - Do not damage the roller tappet.
34044 1
Install the injection pump Unscrew cap (arrow) and remove sealing ring.
34173 1
Note
Ignition off / stop magnet free. Turn in setting bolt (1) to stop.
34174 1
11/2004
2/8
2011
Turn crankshaft until the cam for the respective injection pump is standing on the cam basic circuit (1).
39116 0
Note
- Note the assignment of the roller tappet. - The guide pin (1) on the roller tappet must engage in the groove (2).
1
39117 0
Note
Schematic representation for determining the depth "A".
34177 1
11/2004
3/8
2011
Note
The crankcase rest must be clean. Read and note measured value.
34178 1
Read and note installation dimension "X" from the rating plate of the respective injection pump.
Note
The installation dimension "X" serves exclusively to calculate the compensation gasket. Do not measure on the disassembled injection pump.
34179 1
Determine difference between installation dimension "X" and depth dimension "A".
Example: Installation dimension "X" Depth dimension A Difference 60.00 mm 59.35 mm 0.65 mm
11/2004
4/8
2011
Select compensation gasket according to table.
07 21
12
15
18
21
24
27
34180 1
Note
Since the part number and the gasket thickness are not specified on the compensation gasket, the gasket thickness can be checked with the test template.
39526 0
Note
Note installation position, the recess (arrow) must face the flywheel.
39119 0
11/2004
5/8
2011
Note
Remove the gasket (2) together with the locking pin.
1 2
34183 1
Insert the marking pin (1) in the bore of the injection pump and snap into the deflection lever (arrow). Clamp the bracket of the marking pin.
34184 1
Insert the injection pump centrally to the long holes. Press in injection pump to stop and tighten nuts. Tighten nuts.
07012
34185 1
11/2004
6/8
2011
Loosen clamping bracket and pull out marking pin (1).
34186 1
34187 1
34188 1
11/2004
7/8
2011
Check beginning of pumping if necessary Job card W 07-06-04. Install fuel supply line Job card W 07-10-06. Install injection lines Job card W 07-03-01.
34189 1
11/2004
8/8
2011
W 07-04-01
References
- W 07-03-01 - W 07-06-03 - W 07-06-04 - W 07-10-06
Note
Distinguishing features for the Motorpal injection pump: - Long injection pump housing. - Overflow line on the injection pump.
39484 0
Remove injection pump Remove injection lines Job card W 07-03-01. Remove fuel lines Job card W 07-10-06. Loosen locking screw (1).
Note
The locking screw must be unscrewed for later locking of the injection pump.
39110 0
11/2004
1/8
2011
Note
- Loosen nuts evenly to avoid jamming the injection pump. - Put down the components in the order of installation, note order of cylinders.
39111 0
Pull out roller tappet (arrow) using a suitable tool, e.g. outside locking pliers.
Note
- Put down the components in the order of installation, note order of cylinders. - Do not damage the roller tappet.
39112 0
1
39114 0
11/2004
2/8
2011
Move control linkage to mid position.
Note
Ignition off / stop magnet free. Turn in setting bolt (1) to stop.
1
39115 0
Turn crankshaft until the cam for the respective injection pump is standing on the cam basic circuit (1).
39116 0
Note
- Note the assignment of the roller tappet. - The guide pin (1) on the roller tappet must engage in the groove (2).
Note
When replacing the roller tapper, the assignment of the injection pump to the roller tappet must be observed.
07 16 07 17
1
39117 0
11/2004
3/8
2011
12
15
18
21
24
27
34180 1
Note
Since the part number and the gasket thickness are not specified on the compensation gasket, the gasket thickness can be checked with the test template.
39526 0
Note
Note installation position, the recess (arrow) must face the flywheel.
39119 0
11/2004
4/8
2011
Install the injection pump
Note
When replacing the injection pump the assignment of the injection pump to the roller tappet must be observed.
07 16 07 17
39113 0
6
1 2
Note
Remove the gasket (2) together with the locking pin. Unscrew cap (3) and remove sealing ring.
39120 0
Insert marking pin (1) in the bore (2) of the injection pump.
Note
Do not press in the marking pin completely.
39121 0
11/2004
5/8
2011
Note
The center punch point is visible through the bore for the locking screw.
39122 0
Position the tip of the marking pin (1) in the center punch point. Clamp the clamping bracket (2) of the marking pin.
39123 0
Insert the injection pump centrally to the long holes. Press in injection pump to stop and tighten nuts. Tighten nuts.
07012
39124 0
11/2004
6/8
2011
Loosen clamping bracket and pull out marking pin (1).
39125 0
Press in locking pin (1) with gasket to stop. Tighten cap (2) with new CU sealing ring.
07071
6
1
39126 0
Unscrew setting bolt. Tighten locking screw (1) with new CU sealing ring.
03004
Check beginning of pumping if necessary Job card W 07-06-04. Install fuel lines Job card W 07-10-06. Install injection lines Job card W 07-03-01.
39127 0
11/2004
7/8
2011
11/2004
8/8
2011
W 07-06-03
References
- W 07-04-01 (Motorpal)
Note
- All contact and measuring surfaces must be absolutely clean to rule out measuring errors! - The following work procedure must be performed for every injection pump if necessary.
Remove injection pump and compensation gasket. Removal and installation of roller tappet, visual inspection. Job card W 07-04-01(Motorpal)
39892 1
Note
Presetting of the measuring range approx. 52 mm.
39183 0
11/2004
1/4
2011
39184 3
In hydro-roller tappets, the working piston in the roller tappet (1) must be pressed down (approx. 1 mm) to determine the total depth dimension by turning on the depth measuring screw to the stop (arrow).
39128 0
Measure, read and note the depth dimension "A" from the crankcase rest to the plate spring rest of the roller tappet.
Note
- The crankcase rest must be clean. - Example: 60.25 mm
39184 0
11/2004
2/4
2011
Read and note installation dimension "X" of the rating plate of the respective injection pump.
Note
- The installation dimension "X" serves to calculate the compensation gasket. - Do not measure on the disassembled injection pump. - The exact installation dimension "X" is specified on the rating plate of the injection pump. - Example: 6088 Installation dimension "X" = 60.88 mm
X
39118 0
Read and note value of the pre-stroke correction from the company rating plate.
Note
The value of the pre-stroke correction is specified with a minus () or plus sign. - Example: 16
39877 2
3/4
2011
11/2004
4/4
2011
W 07-06-04
References
- W 07-03-01 - W 07-10-06 (Bosch) - W 07-10-06 (Motorpal) - W 11-00-03
Note
- The description refers to the cylinder at the front cover. The respective ignition UT must be determined by the scale dial when testing on other cylinders.
Check start of pumping Remove injection lines Job card W 07-03-01. Remove fuel lines Job card W 07-10-06 (Bosch) Job card W 07-10-06 (Motorpal) Remove lifting magnet (shutdown magnet) Job card W 11-00-03. Lock camshaft Unscrew cap (1) and remove sealing ring.
39185 0
Insert setting bolt (1) in the bore (2) to lock the camshaft.
39671 0
11/2004
1/8
2011
39672 0
39186 0
Lock the crankshaft Unscrew cap (1) and remove sealing ring.
39187 0
11/2004
2/8
2011
Insert setting bolt (1) in the bore (2) to lock the crankshaft.
1
39516 0
Note
The cylinder at the front cover is now in the ignition UT.
39188 0
Loosen screw (1) and mount pointer with stop device (2). Tighten screw.
39189 0
11/2004
3/8
2011
39190 0
Install overflow pipe (1) on pressure valve holder of the injection pump. Install hose (2) on overflow pipe and supply tank. Install high pressure hand pump (3) to injection pump (4) and supply tank.
Note
Make sure that there is enough fuel in the supply tank.
1 3
2 4
39191 0
Note
Do not tighten locking screw.
39192 0
11/2004
4/8
2011
Unscrew setting bolt for camshaft and crankshaft locking. Turn crankshaft approx. 90 against the engines direction of rotation (arrow).
39193 0
Bleed the suction chamber of the injection pump. Actuate the high pressure hand pump until fuel emerges at the locking screw (1). Tighten the locking screw.
07071
6
1
39192 0
Note
The fuel must flow evenly out of the overflow pipe. Turn the crankshaft slowly and evenly in the direction of rotation of the engine (arrow) until the fuel flow becomes just a dripping.
Note
As soon as the fuel flow becomes a dripping, the beginning of pumping is reached.
39194 0
11/2004
5/8
2011
39195 0
Note
- The beginning of pumping of other injection pumps must be checked by this method. - Determine the ignition UT of the respective cylinder with the dial. Observe the ignition distance. Ignition distance: 2 cylinder engine 3 cylinder engine 4 cylinder engine 180 120 180
Remove dial and pointer, tighten screw. Remove high pressure hand pump and overflow pipe. Unscrew cap (1) and remove sealing ring.
39192 0
11/2004
6/8
2011
Tighten locking screw (1) with new CU sealing ring.
03003
39185 0
Install fuel lines Job card W 07-10-06 (Bosch) Job card W 07-10-06 (Motorpal) Install injection lines Job card W 07-03-01. Install lifting magnet (shutdown magnet) Job card W 11-00-03.
39187 0
11/2004
7/8
2011
11/2004
8/8
2011
W 07-07-01
Remove and install injection valves (in engines with leak fuel line)
Tools
- Commercial tools 8011 - Clamping pliers - Special tools 110 030 - Extractor 150 800 - Extraction tool
References
- W 07-03-01
Note
- Cleanliness is extremely important when working on the injection equipment. - Collect drained operating materials in suitable vessels and dispose of according to regulations. Remove injection valve Remove injection lines Job card W 07-03-01. In engines with leak fuel line Loosen pipe clips (1) and pull off return pipes (2). Unscrew screws and remove overflow pipe (3).
6
1
34031 1
39485 0
11/2004
1/6
2011
Note
- Put down the components in the order of installation, note order of cylinders. - Pull off gaskets burned tight to the cylinder head with extractor and extraction device.
39486 0
Install injection valve Mount new sealing ring (arrow) on injection valve.
34191 1
Note
The leak fuel connection (arrow) must face the Manifold side.
00 81
34192 1
11/2004
2/6
2011
Mount the clamping claw and tighten the screw.
Note
Note installation position of the clamping claw.
34193 1
Tighten screw.
07001
34194 1
1
Attach return hose (2) and fix hose clip with clamping pliers. Insert return hose in holder (arrows).
Note
The rubber hoses must always be renewed.
34202 1
11/2004
3/6
2011
Note
Check return pipe, renew if necessary. Install injection lines Job card W 07-03-01.
34203 1
Install injection valve (leak fuel-less) Mount new sealing ring (1) on injection valve.
39487 0
Note
The flattened side (arrow) must face the Operating side.
1
00 81
39301 0
11/2004
4/6
2011
Mount the clamping claw and tighten the screw.
Note
Note installation position of the clamping claw.
39488 0
Press the clamping claw to touch the gate (arrow) on the injection valve (arrow) and tighten screw (1).
07001
39489 0
11/2004
5/6
2011
11/2004
6/6
2011
W 07-07-02
References
- W 07-07-05 - W 07-07-01
Dismantle injection valve Remove injection valves Job card W 07-07-01. Insert injection valve in holder. Unscrew nozzle clamping nut with long socket.
36271 1
Order of individual disassembly - 1 shim disc - 2 pressure spring - 3 pressure bolt - 4 adapter - 5 Injection nozzle - 6 nozzle lock nut Clean parts in clean diesel fuel and blow dry with air.
6 2 3 4 5
36269 1
11/2004
1/4
2011
Note
- Do not touch the nozzle needle with your fingers. - The nozzle needle and nozzle body are lapped together and may not be switched round or changed individually. - If the nozzle needle slides back with a jolt, clean the injection nozzle in diesel fuel again, renew if necessary. - Also clean the new injection nozzle in clean diesel fuel.
1 2
33904 1
Note
Make sure the centering pins (arrows) are in place.
33905 1
Note
The opening pressure depends on the strength of the shim disc.
36274 1
11/2004
2/4
2011
Insert compression spring.
33907 1
Note
The center joint must face the compression spring.
33908 1
Insert adapter with the centering pins in the bores in the nozzle holder.
Note
The countersink must face the compression bolt.
33909 1
11/2004
3/4
2011
Note
The nozzle needle may not fall out of the nozzle body.
33910 1
33911 1
Remove the injection valve from the holder. Check and set injection valves Job card W 07-07-05 Install injection valves Job card W 07-07-01.
33912 1
11/2004
4/4
2011
W 07-07-05
Caution!
After about three or four actuations of the hand lever, the spring space above the nozzle needle in the injection valve fills up with diesel fuel/test oil. Then it is no longer possible to actuate the hand lever. The nozzle lock nut must be loosened carefully before every test procedure to release pressure from the spring space.
Note
- Cleanliness is extremely important when working on the injection equipment. - Only use pure test oil according to ISO 4113 or clean diesel fuel to test the injection valves.
References
- W 07-07-01
Check the injection valve. Remove injection valves Job card W 07-07-01. Insert injection valve in holder. Loosen the nozzle clamping nut with the long socket approx. 180 (relieve pressure) and re-tighten.
07002
36271 1
Caution!
!
Risk of injury! The fuel penetrates deep into the flesh through the nozzle jet. Risk of blood poisoning!
35889 1
11/2004
1/6
2011
36293 1
Note
- When the hand lever of the nozzle tester has been actuated three or four times, the pressure in the spring space has built back up. - The nozzle clamping nut must be loosened again and re-tightened. - The test must be repeated. - If the measured values of three tests are identical, these can be considered valid.
07002
36293 1
Setting the opening pressure on the injection valve Insert the injection valve in the holder, unscrew the nozzle clamping nut and remove all parts.
36270 1
11/2004
2/6
2011
Order of single part assembly 123456Shim disc Compression spring Compression bolt Adapter Injection nozzle Nozzle clamping nut
6 2 3 4 5
36269 1
Select shim disc, for correcting the opening pressure according to the spare parts list.
Note
A thicker disc gives a higher opening pressure. Assemble injection valve and tighten nozzle clamping nut.
07002
36274 1
Tightness test Blow the injection nozzle and nozzle holder dry with air. Press the hand lever of the tester down slowly until approx. 20 bar below the previously read opening pressure are reached.
36293 1
11/2004
3/6
2011
36294 1
Note
- If the injection nozzle drips, the injection valve must be dismantled and cleaned, the injection nozzle may have to be changed. - Repairs are not permitted.
36295 1
Buzz and jet test Switch off the testers pressure gauge.
Note
The easy action of the nozzle needle in the nozzle body is checked by the acoustic buzz test. Increasing wear in the needle seat of the injection valves changes their buzz behavior.
36296 1
11/2004
4/6
2011
Note
After cleaning, a used injection valve must buzz audibly and atomize the fuel finely when the lever is actuated quickly. The injection nozzle must be changed if it does not buzz after cleaning. The jet profile may deviate considerably from that of a new injection valve.
36296 1
Caution!
!
The pressure in the spring space must be relieved in any case before installing the injection valves.
Loosen the nozzle clamping nut with the long socket approx. 180 (relieve pressure) and re-tighten.
07002
39486 1
11/2004
5/6
2011
11/2004
6/6
2011
W 07-08-01
Remove solenoid valve In BFL engines Unscrew screws (1) and remove air duct cover (2).
2
1 1
39080 0
39665 0
11/2004
1/4
2011
Note
Note clamping direction of the pliers insert. Check components for visible signs of damage.
1
39666 0
Install solenoid valve Mount solenoid valve (1) with new CU sealing ring and tighten with pliers insert.
06094
39667 0
39665 0
11/2004
2/4
2011
In BFL engines Mount air duct cover (1).
Note
The air duct cover must be under the stand plate and the profile rubber (arrows).
39490 0
1 1
39080 0
11/2004
3/4
2011
11/2004
4/4
2011
W 07-08-02
Note
- Collect drained operating materials in suitable vessels and dispose of according to regulations. - A test stand run is necessary to set the charging pressure-dependent full load stop.
Caution!
!
Observe the safety regulations and national specifications for handling fuels!
Remove charging pressure full load stop In FL, BFL engines Unscrew screws (1) and remove the air duct cover (2).
2
1 1
39080 0
Pull the cable plug out of the solenoid valve (1) if available. Pull out the underpressure line (2).
1 2
39381 0
11/2004
1/6
2011
39382 0
39383 0
Unscrew fuel filter (1) with special wrench. Unscrew screws (2) and remove fuel filter console (3) with LDA.
39384 0
11/2004
2/6
2011
Unscrew screws (1), remove cover (2) with diaphragm.
2 1
39385 0
39386 0
Unscrew solenoid valve (1) with pliers insert and remove sealing ring.
Note
- Note clamping direction of the pliers insert. Check components for visible signs of damage.
39387 0
11/2004
3/6
2011
1
39388 0
Note
Note the installation position of the cover, the underpressure connection must face upwards. Tighten screws.
07096
39389 0
Clean the sealing surface on the fuel filter console and crankcase. Renew the gasket (arrow).
39390 0
11/2004
4/6
2011
Mount fuel filter console (1) with LDA and tighten screws (2).
07095
Oil sealing ring on fuel filter lightly. Tighten fuel filter hand tight.
07099
39391 0
Plug fuel pipes and fix pipe clips (1) with clamping pliers.
Note
- Check fuel pipes and renew if necessary. - Observe assignment of the fuel pipes.
39393 0
Plug cable plug to solenoid valve (1) if available. Plug on the underpressure line (2).
1 2
39381 0
11/2004
5/6
2011
Note
The air duct cover must be under the stand plate and the profile rubber (arrows).
39490 0
1 1
39080 0
11/2004
6/6
2011
W 07-10-06
References
- W 08-08-02
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
!
Caution!
Observe the safety regulations and and national specifications for handling fuels!
Remove fuel lines In FL, BFL engines Unscrew screws (1) and remove air duct cover (2).
2
1 1
39080 0
Remove fuel supply line Loosen pipe clip (1) and pull off fuel pipe (2).
39366 0
11/2004
1/4
2011
1 3
2 2
39483 0
Install fuel supply line Push fuel supply line (1) through the profile rubber (arrow) and position. Tighten hollow screws (2) with new CU sealing rings.
1
07015
2 2
39367 0
Attach return hose (1) and fix hose clip with clamping pliers.
Note
Check return pipe, renew if necessary.
34204 1
11/2004
2/4
2011
Attach fuel hose (1) and fix hose clip with clamping pliers.
Note
Check fuel pipe and renew if necessary.
1
34205 1
Note
The air supply cover must be under the stand plate and the profile rubber (arrows).
39490 0
1 1
39080 0
11/2004
3/4
2011
1
34031 1
Install overflow pipe Mount overflow pipe (1), attach hoses and tighten screws.
07062
Attach return hose (2) and fix hose clip with clamping pliers. Insert return hose in holder (arrows).
Note
The rubber hoses must always be renewed.
34202 1
Attach return hose (1) and fix hose clip with clamping pliers.
Note
Check return pipe, renew if necessary. In FL, BFL engines Install oil cooler Job card W 08-08-02.
34203 1
11/2004
4/4
2011
W 07-10-06
Caution!
Observe the safety regulations and and national specifications for handling fuels!
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove fuel lines In FL, BFL engines Unscrew screws (1) and remove air duct cover (2).
2
1 1
39080 0
Remove fuel supply line Loosen pipe clip (1) and pull off fuel pipe.
39494 0
11/2004
1/4
2011
39491 0
Install fuel supply line Push fuel supply line (1) through the profile rubber (arrow) and position. Tighten hollow screws (2) with new CU sealing rings.
07015
39438 0
Attach fuel hose (1) and fix hose clip with clamping pliers.
Note
Check fuel pipe and renew if necessary.
39439 0
11/2004
2/4
2011
Remove overflow pipe In FL, BFL engines Unscrew screws (1) and remove standing plate (2).
1
2
39081 0
Unscrew hollow screws (1), remove overflow pipe (2) and sealing rings.
6
1 1
Note
Remove overflow pipe to flywheel side. Check components for visible signs of damage.
39492 0
Install overflow pipe Mount overflow pipe (2), tighten hollow screws (1) with new CU sealing rings.
1
07061
39492 0
11/2004
3/4
2011
2
Note
- Note different screw length (1 and 2). - The oil cooler must be on the latch (arrow). Tighten screws (1 and 2).
09070
39493 0
Note
The air supply cover must be under the stand plate and the profile rubber (arrows).
39490 0
1 1
39080 0
11/2004
4/4
2011
W 07-10-08
Caution!
Observe the safety regulations and national specifications for handling fuels!
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove fuel filter console Remove fuel filter Unscrew fuel filter (1) with special wrench.
39070 0
Loosen pipe clips (1) with clamping pliers and pull off fuel pipes (2).
2
39067 0
11/2004
1/4
2011
1
39068 0
Install fuel filter console Mount fuel filter console (2) and tighten screws (1).
07082
39068 0
Attach fuel pipes (2) and fix pipe clips (1) with clamping pliers.
Note
- Check fuel pipes and renew if necessary. - Observe assignment of the fuel pipes.
2
39067 0
11/2004
2/4
2011
Install fuel filter Oil sealing ring on fuel filter lightly. Tighten new fuel filter hand tight.
07099
39234 0
11/2004
3/4
2011
11/2004
4/4
2011
W 07-11-01
Caution!
Observe the safety regulations and observe national specifications for handling fuels.
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove fuel pump Pull out oil dipstick (1). Loosen pipe clip (2) with clamping pliers and pull off fuel pipe (3).
6
1
39030 0
Unscrew screws (1). Remove fuel pump (2) and gasket. Check components for visible signs of damage.
39206 0
11/2004
1/2
2011
39207 0
Mount fuel pump. Press in fuel pump to stop and tighten screws (1). Tighten screws.
07024
39225 0
Attach fuel hose (3) and fix hose clip (2) with clamping pliers.
Note
Check fuel pipe and renew if necessary. Insert oil dipstick (1).
39030 0
11/2004
2/2
2011
W 08-04-05
References
- W 04-04-12 (old version) - W 04-04-12 (new version)
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove lube oil pump Remove toothed belt and clamping roller Job card W 04-04-12 (old version) Job card W 04-04-12 (new version) Pull out oil dipstick (1). Unscrew screws (2).
39621 0
Press lube oil pump (1) off the clamping sleeves (2) and remove. Check components for visible signs of damage.
39495 0
11/2004
1/4
2011
1
39496 0
39497 0
Insert lube oil pump (1) and attach to clamping sleeves (2).
39495 0
11/2004
2/4
2011
Tighten screws (1).
08010
Insert oil dipstick (2). Install toothed belt and clamping roller Job card W 04-04-12 (old version) Job card W 04-04-12 (new version).
2
1
1
39498 0
11/2004
3/4
2011
11/2004
4/4
2011
W 08-04-06
References
- W 08-04-07
Auxiliary material
- DEUTZ DW 74
Remove oil intake pipe Remove lube oil tray Job card W 08-04-07 Unscrew screws (1) and remove oil intake pipe (2).
39499 0
Install oil intake pipe Clean the sealing surface on the oil intake pipe and crankcase. Apply sealant DEUTZ DW 74 to the oil intake pipe (arrow).
39351 0
11/2004
1/2
2011
Note
Do not move the sealant when mounting the oil intake pipe.
08015
2
39550 0
11/2004
2/2
2011
W 08-04-07
Auxiliary material
- DEUTZ DW 74
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove lube oil tray Unscrew locking screw (1) and drain engine oil. Tighten locking screw with new sealing ring.
03031
1
39551 0
In engines with connection housing Unscrew screws (arrows) and remove cover plate (1).
39552 0
11/2004
1/4
2011
39628 0
Install lube oil tray Clean the sealing surface on the lube oil tray and crankcase. Apply sealant DEUTZ DW 74 (arrows).
Note
Make sure no sealant gets into the oil channel (1).
1
34253 1
Note
Do not move the sealant when mounting the lube oil tray.
39553 0
11/2004
2/4
2011
Pre-tighten screws at the corners (arrows).
Note
Pre-tighten the screws of the lube oil tray at the corners (arrows) first then tighten all the screws in order.
03030
34255 1
Note
Pay attention to different screw length for cast oil tray.
03030
34256 1
Tightening order 4-cylinder (cast oil tray with cylinder head screws) Tighten all screws in the right order.
Note
Note different screw length.
03030
34257 1
11/2004
3/4
2011
34258 1
34259 1
In engines with connection housing Fit cover plate (1) and tighten screws (arrows).
03085
39552 0
11/2004
4/4
2011
W 08-08-02
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil cooler Unscrew screws (1) and remove air duct cover.
1 1
39080 0
1
2
39081 0
11/2004
1/6
2011
39554 0
1 1
39556 0
39557 0
11/2004
2/6
2011
Press connections (1) into the crankcase to the stop.
Note
The side with the long joint X must face upwards.
39281 0
Note
Insert connections (1) in the bores (arrows).
39622 0
Note
Do not tighten screws.
39559 0
11/2004
3/6
2011
2
Note
- Note different screw length (1 and 2). - The oil cooler must be on the latch (arrow).
1
09070
39493 0
3 2
39623 0
Note
The air duct cover must be under the stand plate and the profile rubber (arrows).
39490 0
11/2004
4/6
2011
Fix air duct cover (2). Tighten screws (1).
09087
1 1
39080 0
11/2004
5/6
2011
11/2004
6/6
2011
W 08-10-06
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil filter cartridge Unscrew oil filter cartridge (1) with special device (2).
39040 0
Install oil filter cartridge Oil the sealing ring of the new oil filter cartridge lightly and screw on hand tight.
08001
39229 0
11/2004
1/2
2011
11/2004
2/2
2011
W 08-11-02
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Note
Overview of valve row assignment - An oil pressure regulating valve (1) is installed as standard in the upper oil channel. The lower oil channels are empty and sealed. - In engines with a heater connection, additional oil pressure regulating valves (2) are available in the lower two oil channels as well as a transfer nipple for supply (3) and return (4).
6
1 3
4 2
39520 0
Remove oil pressure regulating valve (without heater connection) Unscrew cap (1), remove compression spring and valve piston.
Note
When removing the cap the following parts may jump out under the pressure of the compression spring.
39060 0
11/2004
1/8
2011
39061 0
Note
If the wear limit is reached, the compression spring has to be changed.
08 44
39062 0
Install oil pressure regulating valve (without heater connection) Insert valve piston (1) and compression spring (2).
Note
- Use compression spring with green mark (3 bar opening pressure). - Oil the valve piston lightly. - Note installation order.
08 41
34076 1
11/2004
2/8
2011
Tighten cap (1) with new CU sealing ring.
08098
39060 0
Note
In engines without heater connection no oil pressure regulating valves are available in the valve row and the oil channels are fitted with a cap (1).
08098
39065 0
Remove oil pressure regulating valves (with heater connection) Unscrew caps (1) and remove sealing rings.
34081 1
11/2004
3/8
2011
Note
When removing the transfer nipple (2) the following parts may jump out under the pressure of the compression spring.
34080 1
Note
When removing the cap the following parts may jump out under the pressure of the compression spring.
34079 1
Note
Set down the components in the order of installation.
34078 1
11/2004
4/8
2011
Check components for visible signs of wear.
39061 0
Note
If the wear limit is reached, the compression spring has to be changed.
08 44 08 45 08 46
39062 0
Install oil pressure regulating valves (with heater connection) Insert valve piston and compression springs (1, 2 and 3).
Note
- Note the assignment of the compression springs Item 1 2 3 Opening pressure 1.0 bar 1.7 bar 0.3 bar Color marking yellow red blue
39518 0
11/2004
5/8
2011
39518 0
34079 1
Note
The countersink on the sealing rings (arrow) must face the crankcase.
1
39519 0
11/2004
6/8
2011
Tighten the transfer nipple (1) for the heater supply. Tighten transfer nipple (2), with valve seat, for heater return.
1
08061
34080 1
34081 1
11/2004
7/8
2011
11/2004
8/8
2011
W 08-11-07
References
- W 08-10-06
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil filter console Remove oil filter cartridge Job card W 08-10-06. Unscrew hollow screw (1) and remove sealing rings.
39042 0
1 1
39043 0
11/2004
1/2
2011
39044 0
Install oil filter console Clean the sealing surface of the oil filter console and crankcase. Mount oil filter console (2) with new gasket and tighten screws (1).
08003
1 1
39043 0
39042 0
11/2004
2/2
2011
W 08-11-08
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil pressure switch Pull cable plug (1) out of oil pressure switch (2).
39051 0
Unscrew oil pressure switch (1) with sealing ring. Check component for visible signs of damage.
39230 0
11/2004
1/2
2011
39051 0
11/2004
2/2
2011
W 08-11-09
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil pressure sensor Pull off cable plug from oil pressure sensor (1) if available.
39524 0
Unscrew oil pressure sensor (1) with special wrench and remove sealing ring. Check components for visible signs of damage.
39525 0
11/2004
1/2
2011
39525 0
39524 0
11/2004
2/2
2011
W 08-11-12
Auxiliary material
- Assembly sleeve
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil thermostat (oil cooler) In FL, BFL engines Unscrew screws (1) and remove air duct cover (2).
2
1 1
39080 0
1
2
39081 0
11/2004
1/4
2011
Note
When removing, the following parts may jump out under the pressure of the compression spring.
39083 0
39437 0
Note
If the wear limit is reached, the compression spring has to be changed.
08 74
39085 0
11/2004
2/4
2011
Install oil thermostat (oil cooler) Insert oil thermostat (1) with compression spring.
Note
- Oil the oil thermostat lightly. - Note installation order.
39086 0
Note
Use the assembly sleeve.
1
Tighten locking screw (1).
08072
39083 0
In FL, BFL engines Mount the standing plate and turn on the screws.
Note
- Note different screw length (1 and 2). - The oil cooler must be on the latch (arrow). Tighten screws (1 and 2).
09070
39493 0
11/2004
3/4
2011
Note
The air duct cover must be under the stand plate and the profile rubber (arrows).
39490 0
1 1
39080 0
11/2004
4/4
2011
W 08-15-01
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil pressure l-ine Unscrew hollow screws (1), remove oil pressure line (2) and sealing rings. Check components for visible signs of damage.
6
2
1
39397 0
Install oil pressure line Mount oil pressure line (2), tighten hollow screws (1) with new CU sealing rings.
08042
1
39397 0
11/2004
1/2
2011
11/2004
2/2
2011
W 08-15-02
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil return line Unscrew screw (1) and remove holder.
39395 0
Pull oil return line (1) out of the crankcase and pull off from oil return pipe flange support (2).
2 1
39396 0
11/2004
1/4
2011
39398 0
Install oil return line Clean the sealing surface of the turbocharger and oil return pipe flange support. Mount oil return pipe flange support (1) with new gasket and tighten screws (2).
08044
39627 0
Pull new round sealing ring (arrow) onto oil return pipe flange support.
39399 0
11/2004
2/4
2011
Pull new round sealing ring (arrow) onto oil return line.
39378 0
Push oil return line (1) onto oil return line flange support (2) and insert in crankcase.
Note
Oil round sealing rings lightly.
2 1
39396 0
39395 0
11/2004
3/4
2011
11/2004
4/4
2011
W 08-16-01
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil line Pull cable plug (1) out oil pressure switch. Unscrew screws (2), remove fuel filter console (3) and hang aside.
6
1
2
39200 0
Unscrew hollow screws (1), remove oil line (2) and sealing rings. Check components for visible signs of damage.
39202 0
11/2004
1/2
2011
2
39202 0
1
2
39200 0
11/2004
2/2
2011
W 08-16-02
Remove and install oil temperature sensor (in engines with injection adjustment)
Tools
- Commercial tools Caliper gauge
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil temperature sensor (injection adjustment) Unscrew cap (1), remove oil temperature sensor with compression spring and remove slide regulator.
Note
When removing, the following parts may jump out under the pressure of the compression spring.
39045 0
Check components for visible signs of wear. - 1 temperature sensor - 2 pressure spring - 3 slide regulator
39047 0
11/2004
1/2
2011
Note
If the wear limit is reached, the compression spring has to be changed.
08 74
39062 0
Install oil temperature sensor (injection adjustment) Insert temperature sensor, compression spring and slide regulator.
Note
- Oil temperature sensor lightly. - Note installation order. Tighten locking screw (1) with new CU sealing ring.
08053
39045 0
11/2004
2/2
2011
W 08-11-11
References
- W 08-08-02
Note
Collect drained operating materials in suitable vessels and dispose of according to regulations.
Remove oil temperature sensor In FL, BFL engines Remove oil cooler Job card W 08-08-02. Unscrew screw (1).
1
39481 0
39468 0
11/2004
1/4
2011
Note
Note the assignment of the cable plugs.
1 2
39266 0
39265 0
39096 0
11/2004
2/4
2011
Install oil temperature sensor Tighten oil temperature sensor (1) with new sealing ring.
08095
39265 0
Note
Note the assignment of the cable plugs.
1 2
39266 0
In FL, BFL engines Mount air duct (2) and tighten screws (1).
39468 0
11/2004
3/4
2011
1
39481 1
34215 1
11/2004
4/4
2011
W 09-11-01
References
- W 12-02-01 (FL, BFL engines)
Remove cooling blower Remove V-belt Job card W 12-02-01. Unscrew screws (1) and remove air duct cover (2).
2
1 1
39080 0
Remove cable from generator. Unscrew nut (1) and remove cable G1.W (2). Unscrew nut (3) and remove cable G1.D+ (4).
3 4
39560 0
11/2004
1/4
2011
1
39561 0
39611 0
Unscrew screws (1) and remove cooler blower with generator. Check components for visible signs of damage.
1
39562 0
11/2004
2/4
2011
Install cooling blower Mount cooler blower with generator and tighten screws.
09066
39564 0
Note
Note different screw length: Screw M6 x 12 mm (1) Screw M8 x 20 mm (2) Tighten screw (1 and 2).
13092
39271 0
1
39561 0
11/2004
3/4
2011
3 4
39560 0
Note
The air duct cover must be under the stand plate and the profile rubber (arrows).
39490 0
1 1
39080 0
11/2004
4/4
2011
W 09-11-02
References
- W 09-11-01
Dismantle cooling blower Remove cooling blower Job card W 09-11-01. Unscrew screws (arrows) and remove blower jacket inlet (1).
39565 0
Note
Hold shaft.
39566 0
11/2004
1/8
2011
1
39567 0
39568 0
39569 0
11/2004
2/8
2011
Unscrew nut (1) and press out rubber muff (1).
39570 0
Unscrew nuts (1) and press out generator. Visually inspect components and renew if necessary.
39571 0
Note
Note installation position of the generator.
39572 0
11/2004
3/8
2011
Note
Check the installation position again.
09065
39571 0
Note
The stepped side (arrow) must face the generator.
39573 0
39574 0
11/2004
4/8
2011
Mount running wheel (3), V-belt pulley (2) and disc.
Note
Note installation position.
39567 0
Tighten nut.
13021
39575 0
Check gap dimension Press out the protective grille (1) carefully from the blower jacket inlet at the fastening points (arrows).
Note
Do not damage the protective grille.
39576 0
11/2004
5/8
2011
Note
Note the installation position, the gates (arrows) must be in line.
1
09067
2 2
39577 0
Measure the gap dimension with a feeler gauge between the running wheel and the blower jacket inlet.
09 91
39578 0
Note
Spacer discs of 5 to 7 mm are available.
39574 0
11/2004
6/8
2011
Press the protective grille (1) carefully into the blower jacket inlet.
Note
Observe the fastening points.
39579 0
6
1
39580 0
11/2004
7/8
2011
11/2004
8/8
2011
W 09-13-01
Dismantle fan drive If available, unscrew screws (arrows) and remove fan.
34014 1
34005 1
11/2004
1/4
2011
34006 0
34007 1
Pull the inner (1) and outer (2) ball bearing from the shaft. Check components for visible signs of damage.
2 1
Note
The ball bearings must always be renewed.
39008 1
11/2004
2/4
2011
Complete fan drive Press the inner ball bearing (1) over the outer ring up to the stop.
34009 1
Press in the shaft (1) to the stop in the inner ball bearing.
6
1
Note
- Note installation position of the shaft. - Support the inner ring of the ball bearing when pressing in.
34010 1
Press in the outer ball bearing (1) over the outer and inner ring up to the stop.
34011 1
11/2004
3/4
2011
Note
Pay attention to correct fit of the locking ring in the groove.
34006 0
34005 1
Note
Note different strength classes of the screws.
09041
34014 1
11/2004
4/4
2011
W 11-00-03
References
- W 12-02-06 - W 13-02-03 (FM, BFM engines)
Remove lifting magnet (shutdown magnet) In FM, BFM engines Remove generator Job card W 13-02-03. In FL, BFL engines Remove V-belt clamping roller Job card W 12-02-06. Unscrew screw (arrow) and pull off cable plug (1).
39038 0
Unscrew screws (1) and remove lifting magnet (2). Check components for visible signs of damage.
1
39039 0
11/2004
1/2
2011
39036 0
Install lifting magnet Insert lifting magnet (2) and tighten screws (1).
05041
1
39039 0
Plug cable plug (1) and tighten screw (arrow). In FL, BFL engines Install V-belt clamping roller Job card W 12-02-06. In FM, BFM engines Install generator Job card W 13-02-03.
39038 0
11/2004
2/2
2011
W 12-02-01
Caution!
Only test / tighten / renew V-belts with the engine at a standstill.
Note
The V-belt tension of new V-belts must be checked after they have been running for 15 minutes.
Test V-belt Inspect the V-belt visually for wear all round.
39626 0
Renew V-belt Loosen screws (1). Swing V-belt clamping roller (2) to the side (arrow). Remove V-belt.
39276 0
11/2004
1/4
2011
39581 0
Check the V-belt tension with the V-belt tension measuring appliance. Lower indicator arm (1) into V-belt tension measuring appliance (2).
39582 0
Note
The V-belt must be between the guides (arrow).
39583 0
11/2004
2/4
2011
Press the V-belt measuring appliance against the V-belt with the button (1) until you hear it click. Read the measured value at the point of intersection of the indicator arm and the scale (arrow).
Note
Note different unit on the scale.
12 11
12 21
39584 0
6
1
39585 0
11/2004
3/4
2011
11/2004
4/4
2011
W 12-02-01
Caution!
Only test / tighten / renew V-belts with the engine at a standstill.
Note
- The V-belt tension of new V-belts must be checked after they have been running for 15 minutes. - One variant has been described. The procedure is the same accordingly for other variants.
Test V-belt Inspect the V-belt visually for wear all round.
39370 0
Note
Hold nuts (arrow).
3
39371 0
11/2004
1/4
2011
39372 0
Fit V-belt. Tighten V-belt. Push back generator with suitable tool (arrow) and tighten screw (1).
Note
Hold nuts.
13015
1
39373 0
Check the V-belt tension with the V-belt tension measuring appliance. Lower indicator arm (1) into V-belt tension measuring appliance (2).
39582 0
11/2004
2/4
2011
Mount V-belt tension measuring appliance on the V-belt.
Note
The V-belt must be between the guides (arrow).
39522 0
Press the V-belt measuring appliance against the Vbelt with the button (1) until you hear it click. Read the measured value at the point of intersection of the indicator arm and the scale (arrow).
Note
Note different unit on the scale.
12 11
12 21
39523 0
Note
Hold nuts (arrow).
2
13015
3
39371 0
11/2004
3/4
2011
1 2
3
13012
34289 1
Generator fastening with built-up fan drive (building machine design) Tighten screw (1).
13012
2
13015
34292 1
11/2004
4/4
2011
W 12-02-06
References
- W 12-02-01 FL and BFL engines - W 12-02-01 FM and BFM engines
Note
- Only the old version of the clamping roller has been described. - The procedure is the same accordingly for other versions.
Remove V-belt clamping roller Unscrew screws (1) and remove V-belt clamping roller (2). Check component for visible signs of damage.
6
1
39630 0
Install V-belt clamping roller Fit V-belt clamping roller (2) and tighten screws (1). Tighten V-belt. Job card W 12-02-01 (FL and BFL engines) Job card W 12-02-01 (FM and BFM engines).
39630 0
11/2004
1/2
2011
11/2004
2/2
2011
W 12-06-01
Note
Block flywheel with suitable tool. Remove flywheel.
34065 1
Remove stuck flywheel Turn in self-made guide pin (arrow). Apply pressing tool (1) and tighten screws (2).
2 2
34066 2
11/2004
1/2
2011
34066 1
34224 1
Note
- Use new screws. - Block flywheel with suitable tool.
12001
34225 1
11/2004
2/2
2011
W 12-06-03
Caution!
Risk of injury! From hot parts.
References
- W 12-06-01
Remove toothed starter ring Remove flywheel Job card W 12-06-01. Drill toothed starter ring.
Note
Do not damage the flywheel.
33837 1
33838 1
11/2004
1/2
2011
33839 1
Install toothed starter ring Heat up toothed starter ring to max. 220 C. Mount toothed starter ring and contact at collar. Install flywheel. Job card W 12-06-01.
33840 0
11/2004
2/2
2011
W 12-08-02
Auxiliary material
- Graphite grease G 500, 20g tube
Remove hydraulic pump Unscrew hexagon bolts (1), remove hydraulic pump (2) and coupling sleeve.
39090 0
Visually inspect hydraulic pump (1), coupling sleeve (2) and jackets (3) for damage, change if necessary.
1 2
39091 0
11/2004
1/4
2011
Note
The punch-out of the jackets must be aligned to the teeth of the coupling sleeve. Grease the inside teeth of the coupling sleeve with graphite grease G 500.
39092 0
Grease the toothed shaft with graphite grease G 500. Plug the coupling sleeve (2) to the toothed shaft.
Note
- Note installation position. - The teeth of the coupling sleeve must engage the toothed shaft.
34243 1
Insert hexagon bolts in the hydraulic pump. Check the protrusion of the bolts.
Note
The maximum protrusion X may not be greater than 18 mm, renew bolts if necessary or place additional washers under the bolt head.
34244 1
11/2004
2/4
2011
Grease the toothed shaft of the hydraulic pump drive with graphite grease G 500. Insert hydraulic pump (2) with coupling sleeve and tighten hexagon bolts (1).
Note
The teeth of the coupling sleeve must engage the hydraulic pump drive.
12051
39090 0
11/2004
3/4
2011
11/2004
4/4
2011
W 12-08-03
Remove and install toothed belt and clamping roller of the hydraulic pump
Tools
- Commercial tools
!
Caution!
The toothed belt and the clamping roller must be renewed after every disassembly regardless of their time in operation.
References
- W 12-02-01 (FL, BFL engines) - W 12-02-01 (FM, BFM engines)
Remove toothed belt and clamping roller Remove V-belt Job card W 12-02-01 (FL, BFL engines) Job card W 12-02-01 (FM, BFM engines) In FM, BFM engines If available, unscrew screws (1) and remove fan.
39625 0
Unscrew screws (1), flange hub (2) and remove V-belt pulley.
2 1
39461 0
11/2004
1/8
2011
Note
Hold at the center screw.
1
39354 0
39355 0
1
39275 0
11/2004
2/8
2011
Remove adapter (1).
39601 0
Unscrew screw (1) and remove clamping roller (2). Remove toothed belt (3). Check components for visible signs of damage.
6
1 2
3
39590 0
Install toothed belt and clamping roller Insert new clamping roller with the guide fork (1) of the base plate in the guide pin (2) of the hydraulic pump console.
1 2
39591 0
11/2004
3/8
2011
39592 0
Note
Note running direction of the toothed belt. The labeling (arrow) on the toothed belt must be legible from the front.
39593 0
Align the toothed belt so that it is touching the crankshaft gear wheel at the guide joint (1) and the hydraulic pump gear about 4 mm behind the front edge (arrow).
39594 0
11/2004
4/8
2011
Remove locking pin (1).
34235 1
Turn the setting eccenter in the direction of the arrow (counterclockwise) until the pointer of the clamping roller is in line with the notch (1).
Note
Turn the setting eccenter at the hexagon socket. Tighten screw (2).
12052
1
39595 0
Turn the crankshaft 2 turns in the engines direction of rotation (arrow). Check the toothed belt tension.
Note
- The pointer of the clamping roller must be in line with the notch (1). - If the marks are not in line, the toothed belt tension must be corrected.
39596 0
11/2004
5/8
2011
Turn the setting eccenter in the direction of the arrow (counterclockwise) until the pointer of the clamping roller is in line with the notch (1). Tighten screw (2).
12052
1
39595 0
Note
The flattened side (arrow) must face the toothed belt.
1
39597 0
Note
Pay attention to the correct fitting of the protective cover.
12056
1
39275 0
11/2004
6/8
2011
Mount centrifugal disc (1).
Note
The hollow gorge must face the adapter.
1
39598 0
6
1 2
Note
Hold at the center screw.
12031
39599 0
In FM, BFM engines If available, mount V-belt pulley and flange hub (1). Tighten (2) screws alternately.
12031
2 1
2
39462 0
11/2004
7/8
2011
Install V-belt. Job card W 12-02-01 (FL, BFL engines) Job card W 12-02-01 (FM, BFM engines)
39624 0
11/2004
8/8
2011
W 13-01-02
Note
The repair procedure refers to FL, BFL engines. In FM, BFM engines the repair procedure must be performed accordingly.
1 1
39080 0
Remove cable harness Remove cable from generator. Unscrew nut (1) and remove cable G1.W (2). Unscrew nut (3) and remove cable G1.D+ (4).
3 4
39560 0
11/2004
1/8
2011
1
39561 0
Pull out cable plug (1), with black housing, with cable "B3.WK" from the oil temperature sensor. Pull out the cable plug (2), without housing, with cable B3.G from the oil temperature sensor.
39444 0
Pull out the cable plug (1) with cable "F1/B6.WK" from the oil pressure switch.
Note
If available, pull out the cable plug with cable F1/B6.WK and cable plug with cable B6.G from the oil pressure sensor. Pull out the cable plug (2) from the release magnet.
39443 0
11/2004
2/8
2011
Pull off cable plug from solenoid valve (1) if available.
39665 0
Unscrew screw (1) and remove cable plug (2) from engine shutdown.
394410
Pull off profile rubber (1) from the clamping pins and remove the cable harness.
39442 0
11/2004
3/8
2011
Note
The connections to the cable harness depend on the engine requirements.
39440 0
Install cable harness Insert the cable harness in the profile rubber (1) and plug the profile rubber to the clamping pins.
39442 0
Plug the cable plug (2) to the engine shutdown and tighten the screw (1).
394410
11/2004
4/8
2011
Plug cable plug to solenoid valve (1) if available.
39665 0
Plug the cable plug (1) with cable "F1/B6.WK" to the oil pressure switch.
Note
If available, plug the cable plug with cable F1/ B6.WK and cable plug with cable B6.G to the oil pressure sensor. Plug the cable plug (2) with cable to the release magnet.
39443 0
Plug cable plug (1), with black housing, with cable "B3.WK" to the oil temperature sensor. Plug the cable plug (2), without housing, with cable B3.G to the oil temperature sensor.
39444 0
11/2004
5/8
2011
1
39561 0
Connect cable to generator. Attach cable "G1.W" (4) and tighten nut (3) .
13083
3 4
39560 0
Note
The air duct cover must be under the stand plate and the profile rubber (arrows).
39490 0
11/2004
6/8
2011
Fix air duct cover (2). Tighten screws (1).
09087
1 1
39080 0
11/2004
7/8
2011
11/2004
8/8
2011
W 13-02-03
References
- W 12-02-01
Remove generator Remove V-belt Job card W 12-02-01. Unscrew screws (1) and remove air duct cover (2).
2
1 1
39080 0
Remove cable from generator. Unscrew nut (1) and remove cable G1.W (2). Unscrew nut (3) and remove cable G1.D+ (4).
3 4
39560 0
11/2004
1/12
2011
1
39561 0
39611 0
1
39562 0
11/2004
2/12
2011
Remove generator from cooling blower Unscrew screws (arrows) and remove blower jacket inlet (1).
39565 0
6
1
Note
Hold shaft.
39566 0
Remove disc (1), V-belt pulley (2) and running wheel (3).
39567 0
11/2004
3/12
2011
39568 0
39569 0
39570 0
11/2004
4/12
2011
Unscrew nuts (1) and press out generator. Visually inspect components and renew if necessary.
39571 0
Note
Note installation position of the generator.
39572 0
Note
Check the installation position again.
09065
39571 0
11/2004
5/12
2011
1
Note
The stepped side (arrow) must face the generator.
39573 0
39574 0
Note
Note installation position.
39567 0
11/2004
6/12
2011
Tighten nut.
13021
39575 0
Check gap dimension Press out the protective grille (1) carefully from the blower jacket inlet at the fastening points (arrows).
Note
Do not damage the protective grille!
39576 0
Note
Note the installation position, the gates (arrows) must be in line.
1
09067
2 2
39577 0
11/2004
7/12
2011
39578 0
Note
Spacer discs of 5 to 7 mm are available.
39574 0
Press the protective grille (1) carefully into the blower jacket inlet.
Note
Observe the fastening points.
39579 0
11/2004
8/12
2011
Insert rubber muff (1) and tighten nut (2).
13081
39580 0
Install generator Mount cooler blower with generator and tighten screws.
09066
39564 0
Note
Note different screw length: Screw M6 x 12 mm (1) Screw M8 x 20 mm (2) Tighten screw (1).
13092
39271 0
11/2004
9/12
2011
1
39561 0
Plug cable to generator. Attach cable "G1.D+" (4) and tighten nut (3).
13082
3 4
39560 0
Note
The air duct cover must be under the stand plate and the profile rubber (arrows).
39490 0
11/2004
10/12
2011
Fix air duct cover (2). Tighten screws (1).
09087
1 1
39080 0
11/2004
11/12
2011
11/2004
12/12
2011
W 13-02-03
Remove and install generator and holder (in FM, BFM engines)
Tools
- Commercial tools 8189 - Torx tool kit
References
- W 12-02-01
Note
One variant has been described. The procedure is the same accordingly for other variants.
Remove generator Remove cable from generator if available. Item Item Item (1) (2) (3) D+ B+ W
39445 0
1
39447 0
11/2004
1/6
2011
39448 0
39449 0
Unscrew screw (1) and remove clamping bracket (2). Check components for visible signs of damage.
39446 0
11/2004
2/6
2011
Install generator Mount clamping bracket (2) and tighten screw (1).
Note
Note installation position of the clamping bracket.
39446 0
39449 0
39448 0
11/2004
3/6
2011
1
39447 0
Plug cable into generator if available. Item Item Item (1) (2) (3) D+ B+ W
39445 0
Console fastening with built-up fan drive (unit design) Tighten screws (1 and 2).
13010
3 2
34288 1
11/2004
4/6
2011
Console fastening with built-up fan drive (building machine design) Tighten screws (1).
1
13010
2 1
34291 1
11/2004
5/6
2011
11/2004
6/6
2011
W 13-03-02
Remove starter If available, remove the heat shield (1). Unscrew screws (2).
6
2
39380 0
Unscrew screw (1) and remove cable holder (2). Unscrew nut (3) and remove charging current cable (4).
2 4 3
39540 0
11/2004
1/4
2011
1
39541 0
39542 0
2 4 3
39540 0
11/2004
2/4
2011
If available, install the heat shield (1). Tighten screws (2).
13009
39380 0
11/2004
3/4
2011
11/2004
4/4
2011
W 13-06-01
Remove helical heater plugs Unscrew helical heater plugs (1) and remove sealing rings. Check components for visible signs of damage.
39033 0
Install helical heater plugs Tighten helical heater plug (1) with new CU sealing ring.
13031
39035 0
11/2004
1/2
2011
11/2004
2/2
2011
Commercial tools
7
Please send all tool orders directly to: WILBR Wilhelm Bcker GmbH & Co. KG Postfach 14 05 80 D -42826 Remscheid Fax: ++49 (0) 02191 - 8 10 92 Tel.: ++49 (0) 21191 - 9882-860 E-mail address for orders from Germany: [email protected] (Ms. Zarrath) other countries: a. [email protected] (Ms. Karsten)
11/2004
1/8
11/2004
2/8
8005
35410 2
8008
7
2
8008
35411 2
8011
8011
11/2004
39426 0
0312 1640 - 0138
3/8
8018
37506 1
8021
8021
39427 0
8024
Assembly pliers for valve shaft sealing, for removing the valve shaft seal
8024
11/2004
37509 1
0312 1640 - 0138
4/8
8027
39531 0
8036
7
2
8036
39429 0
8049
Force multiplier for center screw on the crankshaft, set with 8036
8049
11/2004
39430 0
0312 1640 - 0138
5/8
8112
39431 0
8115
V-belt pulley tension measuring appliance 150 to 600 N, test the V-belt pulley tension
8115
35416 2
8170
8170
11/2004
39532 0
0312 1640 - 0138
6/8
8189
39432 0
9017
7
2
9017
37511 1
9088
9088
11/2004
39433 0
0312 1640 - 0138
7/8
9090
35420 2
9120
Special bit, 70 mm long IPR 30, 70 mm long, for secure screwing on regulator
9120
39434 0
9122
Special bit, 25 mm long IPR 30, 25mm long, for secure screwing on regulator
9122
11/2004
39435 0
0312 1640 - 0138
8/8
2011
Special tools
8
Please send all tool orders directly to: WILBR Wilhelm Bcker GmbH & Co. KG Postfach 14 05 80 D -42826 Remscheid Fax: ++49 (0) 02191 - 8 10 92 Tel.: ++49 (0) 21191 - 9882-860 E-mail address for orders from Germany: [email protected] (Ms. Zarrath) other countries: a. [email protected] (Ms. Karsten)
11/2004
1/16
11/2004
2/16
100 120
39400 0
100 400
8
4
100 400
37605 1
100 690
100 690
11/2004
39368 0
0312 1641 - 0138
3/16
100 700
39101 0
100.710
100 710
39401 0
100 750
Measuring device with shim discs for piston overhang and front cover in connection with 100 400
100 750
11/2004
39402 0
0312 1641 - 0138
4/16
Note
No longer available. Replaced by marking pin 100 690.
100 880
39403 0
101 100
8
2
101 100
39404 0
101 300
101 300
11/2004
39406 0
0312 1641 - 0138
5/16
101 500
36443 1
101 510
101 510
36444 1
101 910
101 910
11/2004
36449 1
0312 1641 - 0138
6/16
103 030
39533 0
110 030
8
2
35433 2
110 110
Holder for injection valve SW11 to accommodate the injection valve in the vice
110 110
11/2004
35431 2
0312 1641 - 0138
7/16
110 140
39407 0
120 900
120 900
35438 2
120 910
Clamping plate for clamping plate 120 900 if this is not screwed tight
120 910
11/2004
35439 2
0312 1641 - 0138
8/16
121 410
37614 1
130 300
8
2
130 300
35441 2
130 420
130 420
11/2004
36461 1
0312 1641 - 0138
9/16
130 630
39408 0
131 100
131 100
39409 0
131 340
Assembly tool for FL/M engines for piston bolt bush of FL/M engines
131 340
11/2004
39410 0
0312 1641 - 0138
10/16
131 350
39411 0
142 050
8
2
142 050
39412 0
142 850
Assembly tool for camshaft sealing ring without running ring, opposite side to flywheel
142 850
11/2004
39414 0
0312 1641 - 0138
11/16
142 860
39415 0
143 100
143 100
39416 0
143 420
143 420
11/2004
39417 0
0312 1641 - 0138
12/16
143 430
39418 0
143 820
8
2
143 820
39419 0
144 130
144 130
11/2004
39420 0
0312 1641 - 0138
13/16
150 140
39421 0
150 150
150 150
39422 0
150 800
35449 2
11/2004
14/16
170 050
37629 1
170 110
8
2
170 110
39423 0
6067
6067
11/2004
39424 0
0312 1641 - 0138
15/16
6067/114
39369 0
6067/115
Clamping holder
6067/115
39425 0
11/2004
16/16