Workshop Manual competence level 3 D Th is do i cu s al tr m lo ib en w u ed ti o ti sc w n ith i n op yr ou eit ig t o he ht ur r p pr pr rin ot io te ec ra d te o d. gr r ee ele m ct en ro t. ni cf o rm is n ot 2011 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.
Regarding copyright questions and licensing agreements please contact : VS-DI, Mr. Sonntag Tel.: + 49 (0) 221 822-3053 EMail: sonntag.j@deutz.com Deutz AG Service Information Systems Ottostraße 1 D - 51149 Cologne Tel.: + 49 (0) 221-8 22-0 Fax: + 49 (0) 221-8 22-58 50 http://www.deutz.com Printed in Germany All rights reserved 1st edition, 11/2004 Order No.
Workshop Manual 2011 0312 1936 en Note for printers Color: white Paper: Ikonofix 250 g/m2 Workshop Manual 2011
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-Mülheimer Strasse 147-149 D - 51063 Köln 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.
Contents 2011 1 Foreword 2 General 3 User notes 3.1 3.2 3.2.1 3.2.2 3.3 3.4 3.5 4 Technical data 4.1 4.2 5 Test and adjustment data Tightening specifications Job card overview 5.1 5.2 5.
Contents 2011 Notes 1 © 11/2004 2/2 0312 1651 - 0138
2011 1 Foreword 1 © 11/2004 1/4 0312 1650 - 0138
1 Foreword 2011 Notes 1 © 11/2004 2/4 0312 1650 - 0138
1 Foreword 2011 z Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer’s warranty and have a fully functional, ready to use engine at your disposal. z 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.
1 Foreword 2011 1 © 11/2004 4/4 0312 1650 - 0138
2011 2 General 2 © 11/2004 1/4 0312 1649 - 0138
2 General 2011 Notes 2 © 11/2004 2/4 0312 1649 - 0138
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.
2 General 2011 Notes 2 © 11/2004 4/4 0312 1649 - 0138
2011 3 User notes 3 © 11/2004 1/8 0312 1648 - 0138
3 User notes 2011 Notes 3 © 11/2004 2/8 0312 1648 - 0138
3 User notes 2011 3.1 General The maintenance work prescribed in the operating manual and in the workshop manual must be performed on schedule and completely. The maintenance personnel must possess the necessary technical knowledge to perform the work. Safety and protection devices which are removed during maintenance work must be replaced again afterwards. Caution! ! The rules for the prevention of accidents and the safety regulations must be observed during maintenance work.
3 User notes 2011 3.2.2 Disposal regulations The work described in the operating manual and workshop manual necessitates renewal of parts and operating materials. The renewed parts / operating materials must be stored, transported and disposed of properly. The owner himself is responsible for this. Disposal includes recycling and the scrapping of parts / operating materials whereby recycling has priority.
3 User notes 2011 3.4 Job cards The job cards are divided into job cards of the workshop manual e. g. W 04-05-01 and the maintenance manual I 04-05-01. Numbering of job cards Dokumentationsart • Der führende Buchstabe steht für die Art der Dokumentation.
3 User notes 2011 Structure of a job card 1 2 3 Kurbelgehäuse W 00-00-00 4 13 12 11 5 6 3 10 6 9 8 7 © 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.
3 User notes 2011 3.5 Explanation of symbols Caution! ! Auxiliary material For example: Lifting gear, adhesive Tools for example:100 400 - meter 3 Note For example: Cylinder head is dismantled. Always renew when assembling For example: Gaskets References For example: Job card no.
3 User notes 2011 Notes 3 © 11/2004 8/8 0312 1648 - 0138
2011 4 Technical data 4.
4 Technical data 4.
4 Technical data 4.1 Test and adjustment data 2011 00 00 Engine general ID No.
4 Technical data 4.1 Test and adjustment data ID No. 00 71 00 81 2011 Name Ignition sequence Remark Value 2-cylinder 1-2 3-cylinder 1-2-3 4-cylinder 1-3-4-2 Cylinder arrangement 2-cylinder A = Manifold side B = Operating side A 1 2 B © 39617 0 4 Cylinder arrangement 3-cylinder A = Manifold side B = Operating side A 1 2 3 B Cylinder arrangement 4-cylinder A = Manifold side B = Operating side © 39618 0 A 1 2 3 B 01 00 Unit 4 © 39619 0 Cylinder head ID No.
4 Technical data 4.1 Test and adjustment data 2011 ID No. Name 01 05 Bore diameter for valve guide 01 06 Bore diameter for valve guide Additional information Standard • 1. Overmeasure step • Repair • Fit H7 Value Unit 8.000 - 8.025 mm 12.000 - 12.018 mm 01 08 Height of cylinder head Standard 118.00 ±0.1 mm 01 09 Height of cylinder head Undermeasure 117.96 ±0.1 mm 01 10 Valve guide 01 12 External diameter of the valve guide 12.025 - 12.035 mm 8.025 - 8.040 mm • 1.
4 Technical data 4.1 Test and adjustment data ID No. 01 32 4 Name Valve shaft diameter (outlet) 2011 Additional information Value Unit Standard 7.96 mm -0.015 01 33 Valve shaft clearance (inlet) Wear limit 0.5 mm 01 34 Valve shaft clearance (outlet) Wear limit 1.3 mm 01 35 Valve edge strength on valve head (inlet) • Wear limit • FL/M engines 0.8 mm • Wear limit • BFL/M engines 1.4 mm • Wear limit • FL/M engines 1.2 mm • Wear limit • BFL/M engines 1.
4 Technical data 4.1 Test and adjustment data 2011 ID No. 01 47 01 48 Name Valve seat angle (inlet) Valve seat angle (outlet) 01 50 Valve spring 01 51 Valve spring length (unclamped normal) 01 60 Valve clearance 01 61 Valve clearance (inlet) 01 62 Valve clearance (outlet) Additional information Value Unit FL/M engines 45 ° B/FL/M engines 30 ° FL/M engines 45 ° BFL/M engines 45 ° Wire diameter 3.35 mm 38.9 mm Wire diameter 3.40 mm 39.
4 Technical data 4.1 Test and adjustment data ID No. 01 63 Name 2011 Additional information Value Unit Valve clearance setting scheme • Turn over engine up until reaching the valve overlap cyl. no. 1. Note According to the order below (see table) the valve clearance setting is possible with 2 crankshaft revolutions á 360°. Crankshaft setting 1 Cyl. no. 1 = overlap white = not adjustable black = adjustable 4 Crankshaft setting 2 • Turn the crankshaft one rev on (360°).
4 Technical data 4.1 Test and adjustment data 2011 ID No. Name Additional information Value Unit 01 70 toggle lever / toggle lever block 01 72 toggle lever bore for toggle lever axle (outlet) 18 ±0.27 mm 01 73 toggle lever bore for toggle lever axle (inlet) 18 ±0.27 mm 01 74 diameter of the toggle lever axle 17.97 ±0.01 mm 01 93 Roughness of the sealing surface 01 98 Length of the cylinder head screw 02 00 15 - 18 Standard Rz + 0.8 150.000 - 0.
4 Technical data 4.1 Test and adjustment data ID No. 4 Name 2011 Additional information Value 02 20 Lifting journal 02 21 Width of lifting bearing journal 02 22 Diameter of the lifting bearing journal Stroke 112 mm 02 23 Undermeasure step for lifting bearing journal 1. Stage 0.25 2. Stage 0.
4 Technical data 4.1 Test and adjustment data 2011 ID No. Name Additional information Value Unit at a distance of 100 mm max. perm. deviation 0.03 mm 02 42 Parallelism of the con rod to the piston bolt 02 43 Internal diameter of the piston bolt bush • Standard • FL/M engines 26.025 - 26.035 mm • Standard • BFL/M engines 02 45 30.025 - 30.035 Theoretical clearance between Piston bolt bush (con rod) and piston bolt Wear limit 0.
4 Technical data 4.1 Test and adjustment data ID No. 02 71 4 02 72 02 73 Name Diameter of the piston Diameter of the piston Diameter of the piston 02 74 Overmeasure graduation 02 75 Piston overlap for cylinder head gasket 02 76 02 77 © 11/2004 2011 Additional information Value • Measuring point 1 at height 22 mm • FL/M engines 93.920 • Measuring point 1 at height 25 mm • BFL/M engines 93.900 • Measuring point 1 at height 25 mm • BFL engines without cooling duct 93.
4 Technical data 4.1 Test and adjustment data 2011 ID No. 02 78 20 79 Name Piston bolt bore Determine piston class Additional information Value Unit FM engines 26.004 - 26.010 mm BFL/M engines 30.004 - 30.010 mm • Piston class A • Stroke 112 mm • only in FL/M engines 196.380 - 196.490 mm • Piston class B • Stroke 112 mm • only in FL/M engines 196.491 - 196.
4 Technical data 4.1 Test and adjustment data ID No. 02 85 02 86 02 87 4 Name Piston ring joint clearance of the 2nd piston ring B/FL/M engines Piston ring joint clearance of the 3rd piston ring 2011 Additional information Value minute ring 1.5 - 2.0 Wear limit 2.5 Unit mm Roof chamfer ring 0.4 - 0.7 • Wear limit • FL/M engines 1.2 • Oil slit ring • B/FL/M engine 0.3 - 0.
4 Technical data 4.1 Test and adjustment data 2011 ID No. 02 99 03 00 Name Piston ring height 3rd piston ring Additional information Roof chamfer ring Unit 2.975 - 2.990 mm Value Unit Crankcase ID No.
4 Technical data 4.1 Test and adjustment data 04 00 Engine control ID No. 4 2011 Name Additional information Value Unit 04 10 Control times for 1 mm valve clearance 04 11 Inlet opens after UT 3°12’ ° 04 12 Inlet closes after LT 16°48’ ° 04 13 Outlet opens before LT 27°48’ ° 04 14 Outlet closes before UT 4°12’ ° 04 20 Camshaft 04 21 Cam stroke (inlet) 6.6 ± 0.08 mm 04 22 Cam stroke (outlet) 6.8 ± 0.08 mm 04 31 Diameter of the camshaft bearing pin 53.045 - 53.
4 Technical data 4.1 Test and adjustment data 2011 07 00 Fuel system ID No. Name 07 01 Pump 07 02 Make/Type 07 10 injection pump Additional information Value Unit no specification Note Only injection pumps with the same classification may be installed per engine.
4 Technical data 4.1 Test and adjustment data ID No. 07 16 4 Name 2011 Additional information Value Unit • • • • Injection pump length "X" Standard roller tappet Motorpal TN 0428 1810 • Color marking: black • Camshaft stroke 11.0 mm • FL/M engine 60.9 mm • • • • Injection pump length "X" Standard roller tappet Motorpal TN 0428 1814 • Color marking: green • Camshaft stroke 11.0 mm • BFL/M engine 60.
4 Technical data 4.1 Test and adjustment data 2011 ID No. 07 21 Name Value Unit Determined difference (Ss) Dimension "a" of the identification Selection of the shim gasket Part number © 11/2004 Additional information 0417 8522 up to 0.37 9 0428 6587 0.38 – 0.42 14 0417 8523 0.43 – 0.47 12 0428 6588 0.48 – 0.52 17 0417 8524 0.53 – 0.57 15 0428 6589 0.58 – 0.62 20 0417 8525 0.63 – 0.67 18 0428 6590 0.68 – 0.72 23 0417 8526 0.73 – 0.77 21 0428 6591 0.78 – 0.
4 Technical data 4.1 Test and adjustment data ID No.
4 Technical data 4.1 Test and adjustment data 2011 ID No. 08 44 Name Additional information Value Unit Length of the compression spring (green) for the oil pressure regulating valve without heater connection 56.5 mm Length of the compression spring (yellow) for the oil pressure regulating valve with heater connection 80.5 mm 08 45 Length of the compression spring (red) for the oil pressure regulating valve with heater connection 78.
4 Technical data 4.
2011 4 Technical data 4.
4 Technical data 4.
4 Technical data 4.2 Tightening specifications 2011 00000 Engine general ID no. Name Pretightening value 00001 Clamp holder on crankcase 90 Nm 00002 Clamp holder on adapter for assembly block 90 Nm 00003 Engine mount on crankcase elast.
4 Technical data 4.2 Tightening specifications 2011 01000 Cylinder head ID no. Name Pretightening value 01001 Cylinder head on crankcase 30 Nm Re-tightening value Remark • In case of provability use max. 5 times.
4 Technical data 4.2 Tightening specifications 2011 02000 Drive system ID no. Name 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 Pretightening value Re-tightening value Remark • in case of provability use max. 3 times • with lube oil 50 Nm + 60° + 45° 130 Nm + 210° 30 Nm + 60° + 60° • tighten alternately • in case of provability use max.
4 Technical data 4.2 Tightening specifications ID no. Name 2011 Pretightening value Re-tightening value Remark 03007 Locking screws • M18 x 1.5mm - item 5 • Note installation position of the sealing ring! • Always renew after disassembly. 4 50 Nm • M12 x 1.5mm - item 6 26 Nm • M30 x 1.5mm - item 7 • Always renew after disassembly. 95 Nm • M20 x 1.5mm - item 10 • Always renew after disassembly. 56 Nm © 33822 1 • M18 x 1.5mm - item 15 • Always renew after disassembly.
4 Technical data 4.2 Tightening specifications 2011 ID no.
4 Technical data 4.2 Tightening specifications 2011 05000 Speed governing ID no. 4 Name Pretightening value Re-tightening value Remark 05004 Lock nut on setting screw 9.2 Nm 05005 Lock nut on setting screw 6 ± 0.6 Nm Minimum speed 05006 Lock nut on setting screw 16 ± 1.6 Nm Screw spring pre-tension 05007 Lock nut on setting screw 4.5 Nm 05008 Lock nut on setting screw 6 ± 0.6 Nm 05011 Speed governor on connection housing 8.5 Nm 05021 Regulator lever shaft on front cover 9.
4 Technical data 4.2 Tightening specifications 2011 ID no. Name 06030 Air intake pipe on cylinder head Charge air on cylinder head 06094 Solenoid valve on LDA Pretightening value Re-tightening value Remark Re-tightening value Remark 21 Nm 21 Nm 10 Nm 07000 Fuel system ID no.
4 Technical data 4.2 Tightening specifications ID no. Name 2011 Pretightening value 07095 Charge pressure-dependent full load stop (LDA) on crankcase 22 Nm 07096 Cap on charge pressuredependent full load stop (LDA) 8 Nm 07099 Fuel filter on fuel filter console 9 ± 1 Nm Re-tightening value Remark hand tight 08000 Lube oil system 4 ID no.
4 Technical data 4.2 Tightening specifications 2011 ID no.
4 Technical data 4.2 Tightening specifications 2011 09000 Cooling system ID no. Name 09041 Fan on fan drive Pretightening value Re-tightening value Remark 22 Nm M8 x 22mm / bolts 8.8 30 Nm M8 x 20mm / bolts 10.
4 Technical data 4.2 Tightening specifications 2011 ID no. Name 12043 V-belt tensioning roller on holder Pretightening value Re-tightening value • M8 x 20mm • M8 x 30mm 21 Nm 12046 V-belt pulley on fan mounting 22 Nm 12047 V-belt guard on front cover 21 Nm 12051 Hydraulic pump on hydraulic pump console 57 Nm 12052 Toothed belt tensioning roller on hydraulic pump console 8 +2 Nm 12056 Protective hood on hydraulic pump console 8.
4 Technical data 4.2 Tightening specifications ID no.
2011 5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
2011 5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
2011 5 Job card overview 5.
5 Job card overview 5.3 Job card references 2011 Explanation of job card reference: Owing to the job card structure, individual parts of the work processes may overlap or repeat. Illustrations of the same working environment may also deviate slightly.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
5 Job card overview 5.
2011 6 Job cards 6 © 11/2004 1/2 0312 1647 - 0138
6 Job cards 2011 Notes 6 © 11/2004 2/2 0312 1647 - 0138
Engine general W 00-02-06 2011 W 00-02-06 Check compression Tools References - Commercial tools 8005 - Compression tester 8189 - Torx tool kit - W 01-01-01 - W 07-07-01 - W 08-08-02 - Special tools 100 120 - Connecting piece 6 Check compression z Check and set valve clearance Î Job card W 01-01-01. z Remove injection valves Î Job card W 07-07-01. In FL, BFL engines z Install oil cooler Î Job card W 08-08-02. © 39104 0 z Insert adapter (1) with sealing ring.
Engine general W 00-02-06 2011 z Fit clamping claw (1) and tighten screws (2) . Note Note installation position. 07001 1 2 © 39106 0 6 z If necessary, mount adapter (1) on connection piece. 1 © 39107 0 z Connect compression tester to connection piece or adapter. z Turn over engine with starter.
Engine general W 00-02-06 2011 No. Kompression in bar Compression value in bar Pression en bar Dat. _________ 30 35 40 10 15 20 25 Zyl. z 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.
Engine general W 00-02-06 2011 Notes 6 © 11/2004 4/4 0312 1553 - 0138
Engine general W 00-05-01 2011 W 00-05-01 Mount engine on assembly stand and disassemble Tools References - Commercial tools - W 13-03-02 - Special tools 6067 - Engine assembly block 6067/115 - Clamping holder 6067/114 - Support arm 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.
Engine general W 00-05-01 2011 In FL, FM engines z Unscrew screw (1) and remove holder. z Pull out stopper (2). 2 1 © 39502 0 6 In BFL, BFM engines z Unscrew screw (1) and remove holder. z Remove oil return pipe (arrow). 1 © 34015 1 z Mount clamping holder (1) on the Manifold side and tighten screws (2).
Engine general W 00-05-01 2011 z Mount clamping holder on engine assembly block. z Fit counter plate (1). z Insert screws and nuts (2). 1 00002 z Unhook engine from workshop crane and unscrew eyebolt. 2 © 39504 0 6 Remove engine from assembly block. z Screw in eyebolt. z Hang engine on suitable workshop crane. z Unscrew nuts (2), remove counter plate (1) and bolts. 1 2 © 39504 0 z Unscrew screws (2) and remove clamping holder (1).
Engine general W 00-05-01 2011 In FL, FM engines z Pull new round sealing ring (arrow) onto stopper. © 39505 0 6 z Insert stopper (2). Note Oil round sealing ring lightly z Mount holder and tighten screw (1). 08046 2 1 © 39502 0 In BFL, BFM engines z Pull new round sealing rings onto screwed socket (arrow) and oil return pipe.
Engine general W 00-05-01 2011 z Insert oil return pipe (arrow). z Mount holder and tighten screw (1). 08044 1 © 34015 1 6 z Mount engine bearing (2) and tighten screws (1). 00003 z Unhook engine from workshop crane and unscrew eyebolt.
Engine general W 00-05-01 2011 Notes 6 © 11/2004 6/6 0312 1554 - 0138
Cylinder head W 01-01-01 2011 W 01-01-01 Check and set valve clearance Tools - Commercial tools Feeler gauges 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. 6 Removal z Unscrew screws (arrows), remove starter cylinder head cover (1) and gasket. 1 © 39131 0 Set engine to valve overlap z Turn crankshaft until reaching valve overlap on cylinder no. 1.
Cylinder head W 01-01-01 2011 Note Valve overlap means: - Outlet valve not yet closed. - The inlet valve starts opening. © 39133 0 6 Check valve clearance z Arrangement of inlet and outlet valves. - IN = inlet valve - EX = outlet valve EX IN EX IN EX IN EX IN © 39134 0 z 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.
Cylinder head W 01-01-01 2011 Setting valve clearance z Loosen lock nut (1). z Correct valve clearance by turning the setting screw (2). Note 2 - 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 1 © 39136 0 6 z Tighten lock nut (1). Note Do not turn the setting screw (2) when tightening the lock nut. 01003 z Check the valve clearance again with a feeler gauge blade.
Cylinder head W 01-01-01 2011 z Mount cylinder head cover and tighten screws alternately.
Cylinder head W 01-02-02 2011 W 01-02-02 Remove and install toggle lever and toggle lever block Tools References - Commercial tools - W 01-01-01 6 Remove toggle lever and toggle lever block z Unscrew screws (arrows). Remove cylinder head cover (1) and gasket. 1 © 39131 0 z 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.
Cylinder head W 01-02-02 2011 z Remove stop rods (1). Note Set down the components in the order of installation. z Check stop rods for visible signs of damage. 1 1 © 39141 0 6 z Insert stop rods (1). 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 z Loosen the lock nuts of the setting screws and turn back the setting screws. 1 z Mount toggle lever block (1).
Cylinder head W 01-02-02 2011 z 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 z Check and set valve clearance Î Job card W 01-01-01. 1 © 39143 0 6 z Clean the sealing surface on the cylinder head cover and cylinder head. z Fit gasket. Note Note installation position, the gate (arrow) must face the front cover.
Cylinder head W 01-02-02 2011 Notes 6 © 11/2004 4/4 0312 1556 - 0138
Cylinder head W 01-02-06 2011 W 01-02-06 Disassemble and complete, check toggle lever and toggle lever block Tools References - Commercial tools Internal measuring device Micrometer gauge - W 01-02-02 6 Dismantle toggle lever block 1 z Remove toggle lever and toggle lever block Î Job card W 01-02-02. z Remove locking rings (1). 1 © 39144 0 z Remove toggle lever.
Cylinder head W 01-02-06 2011 Check toggle lever z Measure toggle lever bore with internal measuring device. 01 72 01 73 Note If the wear limit is reached, change the toggle lever. © 39032 0 6 z Unscrew lock nut (1) and turn out setting screw (1). 1 2 © 39146 0 z Check components for visible signs of wear. z Check oil channels (arrows) for free passage.
Cylinder head W 01-02-06 2011 z Turn setting screw (2) into the toggle lever and tighten the lock nut (1). 1 2 © 39146 0 6 Check the toggle lever axis z 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 z Push toggle lever (1) onto the toggle lever axle (2). Note - Oil the toggle lever axle (2) lightly.
Cylinder head W 01-02-06 2011 z Install locking rings (1). Note Pay attention to correct fit of the locking ring in the groove. 1 z Install toggle lever and toggle lever block Î Job card W 01-02-02.
Cylinder head W 01-04-04 2011 W 01-04-04 Remove and install cylinder head Tools References - Commercial tools 8189 - Torx tool kit - W 01-02-02 - W 06-07-03 - W 07-07-01 - W 09-11-01 - W 13-02-03 - Special tools 100 400 - Meter 100 750 - Measuring device 6 Remove cylinder head z Remove air intake pipe Î Job card W 06-07-03. z Remove injection valve Î Job card W 07-07-01. z Remove toggle lever and toggle lever block Î Job card W 01-02-02. In FM, BFM engines z Remove generator Î Job card W 13-02-03.
Cylinder head W 01-04-04 2011 z Unscrew screws (arrows), remove cylinder head (1) and gasket. z Clean sealing surfaces on cylinder head and crankcase. 1 © 39155 0 6 Determine cylinder head gasket 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 z Turn crankshaft until the piston closes flush with the crankcase.
Cylinder head W 01-04-04 2011 z Mount shim (1) and measuring bridge (2) on crankcase. z Insert meter in measuring bridge and position the stylus with pre-tension on the piston base (arrow). 2 z Turn the crankshaft on evenly until the reversal point of the pointer on the meter is reached. The piston is now in UT. 1 1 © 39157 0 6 Determine piston overlap z Move measuring bridge and shim. z Place the stylus of the meter under pre-tension on the sealing surface of the crankcase (arrow).
Cylinder head W 01-04-04 2011 z Move the measuring bridge on the shims so that the stylus is applied to the specified measuring points. Note - Measuring points, see schematic diagram. - The stylus may not be positioned on the labeling of the piston. z Note the greatest measured value. © 39159 0 6 z Select the cylinder head gasket according to the greatest measured piston overlap. 02 75 02 76 02 77 z Example: Piston overlap = 0.73 mm, corresponds to cylinder head gasket with 2 notches (arrow).
Cylinder head W 01-04-04 2011 z 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 6 z 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 Tightening order 2-cylinder z Tighten all bolts in the right order.
Cylinder head W 01-04-04 2011 Tightening order 3-cylinder z Tighten all bolts in the right order. 01001 7 3 4 6 5 1 2 8 © 39153 0 6 Tightening order 4-cylinder z Tighten all bolts in the right order. 01001 8 6 4 5 9 10 3 1 2 7 © 39154 0 In FM, BFM engines z Install generator Î Job card W 13-02-03.
Cylinder head W 01-04-04 2011 In FL, BFL engines z Install cooling blower Î Job card W 09-11-01. z Install toggle lever and toggle lever block Î Job card W 01-02-02. z Install injection valve Î Job card W 07-07-01. z Install air intake pipe Î Job card W 06-07-03.
Cylinder head W 01-04-04 2011 Notes 6 © 11/2004 8/8 0312 1558 - 0138
Cylinder head W 01-05-01 2011 W 01-05-01 Remove and install valves Tools References - Commercial tools Caliper gauge 8024 - Assembly pliers 9017 - Assembly lever - W 01-04-04 - Special tools 120 900 - Clamping block 120 910 - Clamping plate 121 410 - Assembly tool 6 Remove valves z Remove cylinder head Î Job card W 01-04-04. 1 z Install clamping block (1) on clamping plate (2). z Install cylinder head on clamping block. 2 © 39164 0 z Install valve assembly lever (1).
Cylinder head W 01-05-01 2011 z Remove valve shaft seal with valve sealing ring pliers. © 39166 0 6 z Clean cylinder head, check and inspect for damage. z Check components for visible signs of damage. © 39167 0 Install valves z Measure valve spring length with caliper gauge. Note If the wear limit is reached, the valve spring has to be changed.
Cylinder head W 01-05-01 2011 z 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. 1 © 33889 1 6 z Push the new valve shaft seal over the protective sleeve (arrow). © 33890 1 z Remove the protective sleeve. z Press the valve shaft seal in with the assembly tool (1) until it touches.
Cylinder head W 01-05-01 2011 z Insert valve spring (1) and valve spring head (2). 2 1 © 39169 0 6 z Install valve assembly lever. z 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. 1 © 39170 0 z Remove valve assembly lever z Remove cylinder head from clamping block. z Install cylinder head Î Job card W 01-04-04.
Cylinder head W 01-05-04 2011 W 01-05-04 Check valves Tools References - Commercial tools Micrometer gauge Caliper gauge - W 01-05-01 Note - Clean all valves. - If the wear limit is reached, the valve has to be changed. 6 Valve shaft diameter z Remove valves Î Job card W 01-05-01. z Measure valve shaft diameter with micrometer screw. 01 31 01 32 © 42182 0 Valve edge strength z Measure valve edge thickness with caliper gauge.
Cylinder head W 01-05-04 2011 Valve plate diameter z Measure head diameter with caliper gauge. 01 37 01 38 z Install valves Î Job card W 01-05-01.
Cylinder head W 01-06-03 2011 W 01-06-03 Check valve guide Tools References - Commercial tools Magnetic measuring stand - W 01-05-01 - Special tools 100 400 - Meter Note - New valves are used for testing. - If the wear limit is reached, the valve guide has to be changed. 6 Check valve guide z Remove valves Î Job card W 01-05-01. z Check valve guide for visible signs of wear. z Attach magnetic measuring stand and insert meter. z Insert new valve.
Cylinder head W 01-06-03 2011 z Remove magnetic measuring stand and meter. z Install valves Î Job card W 01-05-01.
Cylinder head I 01-07-07 2011 I 01-07-07 Machine valve seat ring Tools References - Commercial tools Caliper gauge Valve seat rotating device - 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 manufacturer’s operating manual. 6 Check valve seat ring z Check valve lag Î Job card W 01-07-08. z Remove valves and valve shaft seals Î Job card W 01-05-01.
Cylinder head I 01-07-07 2011 Machine valve seat ring z Install valve seat rotating device Note Observe different valve seat angles. 01 47 01 48 © 39353 0 6 z 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 z Measure valve seat width with caliper gauge.
Cylinder head I 01-07-07 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 1 01 42 z Remove valve seat rotating device z Remove chips. 2 © 39393 0 6 Check contact pattern z Coat the sitting surface of the valve cone thinly with varnish. z Insert valve and turn 45° to 90°. z Remove the valve and check the contact pattern.
Cylinder head I 01-07-07 2011 Notes 6 © 11/2004 4/4 0312 1562 - 0138
Cylinder head W 01-07-08 2011 W 01-07-08 Check valve lag Tools References - Commercial tools Depth-measuring appliance - W 01-04-04 - Special tools 120 900 - Clamping block 120 910 - Clamping plate Note If the wear limit is reached, the valve seat ring or the valve itself must be changed, both together if necessary. 6 Check valve lag z Remove cylinder head Î Job card W 01-04-04. 1 z Install clamping block (1) on clamping plate (2). z Mount the cylinder head on the clamping block.
Cylinder head W 01-07-08 2011 z Remove cylinder head from clamping block (1). z Remove clamping block from clamping plate (2). 1 z Install cylinder head Î Job card W 01-04-04.
Drive system W 02-01-07 2011 W 02-01-07 Check crankcase Tools References - Commercial tools Magnetic measuring stand Micrometer gauge Internal measuring device Prisms Hardness tester - 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 - Special tools 100 400 - Meter Note If the crankshaft is worn it is possible to have the crankshaft repaired in our Service Centers.
Drive system W 02-01-07 2011 Note Schematic representation for measuring the bearing pins at the points ”1” and ”2” in the levels ”a” and ”b”. © 36424 1 6 Check the diameter of the main bearing pins z 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 z Measure lifting bearing journal with micrometer gauge.
Drive system W 02-01-07 2011 Check runout z Attach magnetic measuring stand and insert meter. z Apply stylus to the main bearing pin with pre-tension (arrow) and set meter to ”0”. z Turn crankshaft evenly and check shells. 02 26 z Remove magnetic measuring stand and meter. © 39180 0 6 Measure fit bearing width z Set micrometer gauge to 35 mm. z Push the internal measuring device between the test surfaces of the micrometer gauge and set to ”0”.
Drive system W 02-01-07 2011 Check axial clearance z Place startup ring halves on fit bearing cover (arrows). z Measure width with micrometer gauge. z Note the measured value (dimension ”B”). Note The dimension "B" is required for determining the axial clearance. © 35827 1 6 z Determine axial clearance Axial clearance = dimension ”A” – dimension ”B” Example: 02 34 Dimension "A" 35.00 mm - Dimension ”B” 34.80 mm = Axial clearance 0.20 mm z Use the appropriate startup ring halves.
Drive system W 02-02-02 2011 W 02-02-02 Renew crankshaft sealing ring (flywheel side) Tools References - Commercial tools Assembly lever - W 12-06-01 - Special tools 142 860 - Assembly tool 6 Remove crankshaft sealing ring z Remove flywheel Î Job card W 12-06-01. z Loosen the crankshaft sealing ring (arrow) in its seat with a pin. © 39506 0 z Carefully drill a hole (at least 3 mm Ø) diameter in the crankshaft sealing ring.
Drive system W 02-02-02 2011 z Turn in self-tapping screw (1) with washer. 1 © 39508 0 6 z Remove crankshaft sealing ring with suitable tool, e.g. assembly lever. z Visually inspect the crankshaft flange and rear cover. © 39509 0 Install crankshaft sealing ring z Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. z Fit the crankshaft sealing ring (1) to the assembly sleeve (2). 2 1 Note The sealing lip must face the crankshaft in assembly.
Drive system W 02-02-02 2011 Note Installation depthe X = approx. 2.5 mm of the crankshaft sealing ring. X © 39352 0 6 z Drive in crankshaft sealing ring with assembly tool. Note Note installation depth. z Install flywheel. Î Job card W 12-06-01.
Drive system W 02-02-02 2011 Notes 6 © 11/2004 4/4 0312 1565 - 0138
Drive system W 02-02-04 2011 W 02-02-04 Renew crankshaft sealing ring (opposite side to flywheel) Tools References - Commercial tools 9017 - Assembly lever - W 03-08-01 - W 04-04-12 old version - W 04-04-12 new version - Special tools 100 700 - Setting bolt 142 850 - Assembly tool 6 Remove crankshaft sealing ring z Remove toothed belt and clamping roller, loosen camshaft toothed belt wheel Î Job card W 04-04-12 old version. Î Job card W 04-04-12 new version.
Drive system W 02-02-04 2011 z Turn in self-tapping screw (1) with washer. 1 © 39652 0 6 z Remove crankshaft sealing ring with suitable tool, e.g. assembly lever. z Visually inspect the running surface of the crankshaft flange and front cover. © 39653 0 Install crankshaft sealing ring z Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. z Fit the crankshaft sealing ring (1) to the assembly tool (2). 1 2 Note The sealing lip must face the crankshaft in assembly.
Drive system W 02-02-04 2011 z Mount the crankshaft sealing ring with the assembly tool and turn in the screw. © 39654 0 6 z Pull in the assembly tool to the stop by turning in the screw. Note The installation depth of the crankshaft sealing ring is determined by the assembly tool. z Unscrew screw and remove assembly tool. z Install crankshaft toothed wheel Î Job card W 03-08-01. z Install toothed belt and clamping roller, fix camshaft toothed belt wheel Î Job card W 04-04-12 old version.
Drive system W 02-02-04 2011 Notes 6 © 11/2004 4/4 0312 1566 - 0138
Drive system W 02-03-01 2011 W 02-03-01 Check con rod Tools References - Commercial tools Micrometer gauge Internal measuring device Con rod test device 8021 - Socket size 15 - W 02-03-03 - Special tools 100 400 - Meter Note The con rod is removed and the piston disassembled. 6 Check piston bolt bush Prepare internal measuring device z Mount probe bolt for the appropriate measuring range in the internal measuring device. z Mount meter with approx. 1 mm pre-tension in the internal measuring device.
Drive system W 02-03-01 2011 z Measure piston bolt bush with internal measuring device. Insert the internal measuring device in the piston bolt bush. z 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 - Piston bolt bush pressed in. - Measuring points, see schematic diagram. 02 43 z Remove and install piston bolt bush Î Job card W 02-03-03.
Drive system W 02-03-01 2011 Check the con rod bearing bore z Mount con rod bearing cover on con rod. Note 1 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 6 z Tighten nuts. Note Use a twelve-edge box wrench. 02020 © 39323 0 Prepare internal measuring device z Mount probe bolt for the appropriate measuring range in the internal measuring device. z Mount meter with approx.
Drive system W 02-03-01 2011 Note Schematic representation for measuring the con rod bearing bore at the points ”a” and ”b” in the levels ”1” and ”2”. a b a b 1 2 © 37239 0 6 z Measure con rod bearing bore with internal measuring device. Insert internal measuring device in the con rod bearing bore. z Balance the internal measuring device respectively at the given measuring points and read the measured value at the reversal point of the pointer.
Drive system W 02-03-01 2011 z Insert con rod bearing shell in the appropriate con rod bearing cover. Note The twist protection (1) must engage in the groove (2). 2 1 © 39326 0 6 z 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 z Tighten nuts. Note Use a twelve-edge box wrench.
Drive system W 02-03-01 2011 Prepare internal measuring device z Mount probe bolt for the appropriate measuring range in the internal measuring device. z Mount meter with approx. 1 mm pre-tension in the internal measuring device. z Set micrometer gauge to 55 mm. z Balance the internal measuring device between the test surfaces of the micrometer gauge and set the meter at the reversal point of the pointer to ”0”.
Drive system W 02-03-01 2011 Determine con rod bearing clearance Example: 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 Dimension "A" 35.00 mm — Dimension ”B” 34.80 mm = Con rod bearing clearance 0.20 mm 02 57 z Unscrew nuts and remove con rod bearing cover. 6 Check con rod parallelism z Check con rod without bearing shells on the con rod test device.
Drive system W 02-03-01 2011 Notes 6 © 11/2004 8/8 0312 1567 - 0138
Drive system W 02-03-03 2011 W 02-03-03 Remove and install piston bolt bush Tools Note - Commercial tools - The con rod is removed and the piston disassembled. - The piston bolt bush must be mechanically machined after assembly. - Special tools 131 340 - Assembly tool for FL/M engines 131 350 - Assembly tool for BF/M engines References - W 02-09-03 6 z Remove piston and con rod Î Job card W 02-09-03. 4 Remove piston bolt bush z Insert extraction socket (1) in piston bolt bush.
Drive system W 02-03-03 2011 Install piston bolt bush z Mount piston bolt bush on con rod. 1 Note Pay attention to matching of the oil bores (1) in the piston bolt bush and the con rod. © 39332 0 6 z Insert extraction socket (1) in new piston bolt bush. z Place counterbearing (2) with the closed side on the con rod and insert the screw (arrow). 1 z Fit washer and tighten nut. 2 © 39333 0 z Pull in piston bolt bush flush. z Remove disassembly tool.
Drive system W 02-03-03 2011 Note The piston bolt bush must be mechanically machined after assembly. 02 61 02 43 02 45 z Install piston and con rod Î Job card W 02-09-03.
Drive system W 02-03-03 2011 Notes 6 © 11/2004 4/4 0312 1568 - 0138
Drive system W 02-04-01 2011 W 02-04-01 Remove and install crankshaft Tools References - Commercial tools 8021 - Socket size 15 - 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 6 Remove crankshaft z Remove rear cover (flywheel side) Î Job card W 03-09-01. z Remove front cover (opposite side to flywheel) Î Job card W 03-08-01.
Drive system W 02-04-01 2011 Remove all con rod bearing covers z Unscrew nut (1) and remove con rod bearing cover (2). 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. 2 1 z Remove con rod bearing cover and con rod bearing shell. © 39336 0 6 Remove fit bearing and all main bearing covers z Unscrew screws (1).
Drive system W 02-04-01 2011 z Remove crankshaft. © 39339 0 6 z 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. z Check components for visible signs of wear. 1 z Check axial clearance of crankshaft Î Job card W 02-01-07.
Drive system W 02-04-01 2011 Install crankshaft z Insert main bearing shells in the crankcase. Note 1 - Note the assignment of the bearing shell. - The twist protection (1) must engage in the groove (2). 2 © 39341 0 6 z Insert main bearing shell in the appropriate main bearing cover. 1 Note - Note the assignment of the main bearing cover. - The twist protection (1) must engage in the groove (2). 2 © 37043 1 z Insert con rod bearing shell in the con rod.
Drive system W 02-04-01 2011 z 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). 2 1 © 39343 0 6 z Check all clamping bushes are in place (arrows). © 39344 0 z Oil all bearing surfaces on the bearing pin and bearing shells lightly. z Insert the crankshaft carefully in the crankcase. Note Do not jam the con rods when inserting the crankshaft.
Drive system W 02-04-01 2011 z Stick both startup ring halves with guide lugs (arrow) to the fir bearing cover with a little grease. Note 1 - 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.
Drive system W 02-04-01 2011 Install all con rod bearing covers z Pull the con rods carefully onto the lifting bearing journal. © 39348 0 6 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. 1 © 39349 0 z Tighten nuts. Note - Con rod bolts and nuts can be used a max.
Drive system W 02-04-01 2011 z Clean the sealing surface on the oil intake pipe and crankcase. z Apply sealant DEUTZ DW 74 to oil suction pipe (arrow). © 39351 0 6 z Mount oil intake pipe (2) and tighten screws (1). Note Do not move sealant when mounting the oil intake pipe. 2 08015 1 © 39335 0 z Screw setting bolts (1) into the crankcase to the stops.
Drive system W 02-04-01 2011 z Turn the crankshaft carefully in the direction of rotation of the engine (clockwise) until it touches the setting bolts. z Install rear cover (flywheel side) Î Job card W 03-09-01. z Install front cover (opposite side to flywheel) Î Job card W 03-08-01.
Drive system W 02-04-01 2011 Notes 6 © 11/2004 10/10 0312 1569 - 0138
Drive system W 02-09-03 2011 W 02-09-03 Remove and install pistons and con rod Tools References - Commercial tools 8021 - Socket size 15 - W 01-04-04 - W 02-10-03 - W 08-04-06 - Special tools 101 910 - Device 130 630 - Piston ring tensioning band 131 100 - Disassembly tool 6 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.
Drive system W 02-09-03 2011 Remove piston and con rod. z Remove cylinder head Î Job card W 01-04-04. z Remove oil intake pipe Î Job card W 08-04-06. z Pull out oil dipstick (1). 1 © 39219 0 6 Remove con rod bearing cover z Set lifting bearing journal in the lower dead point. z Unscrew nuts (1). Note - Use a twelve-edge box wrench. - Put down the components in the order of installation, note order of cylinders. 1 00 81 2 z Remove con rod bearing cover (2) and con rod bearing.
Drive system W 02-09-03 2011 z Remove con rod bearing shells (1). z Check components for visible signs of wear. 1 1 © 39240 0 6 Remove piston from con rod. z Insert disassembly tool (1) in the piston bolt. 1 Caution! ! Risk of injury! The spring ring jumps off. Always use the disassembly tool. © 39244 0 z Place suitable tool in recess (1). z Remove spring rings (2) on both sides and press out piston bolt (3). Note The tools are not inserted for a better representation.
Drive system W 02-09-03 2011 Only in FL, FM engines Determine piston class Note If the crankshaft and/or the crankcase are replaced, the piston class must be redetermined for every single cylinder. z Place lifting bearing journal of the respective cylinder in the upper dead point (UT). © 39250 0 6 z 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.
Drive system W 02-09-03 2011 Complete the con rod and the piston X z 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 z Insert con rod in piston. Note 6010 The symbol flywheel/crankshaft (1), on the piston base, must face left and the numeric identification (2) on the con rod up. 2 1 © 39259 0 z Oil lightly and press in the piston bolt. z Insert the second spring ring.
Drive system W 02-09-03 2011 Install piston and con rod z 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). 2 1 © 39282 0 6 z Insert con rod bearing shell in the appropriate con rod bearing cover. Note The twist protection (1) must engage in the groove (2). 2 1 © 39283 0 z Arrange piston ring joints offset by about 120°. z Check piston rings and piston ring grooves Î Job card W 02-10-03.
Drive system W 02-09-03 2011 z Oil cylinder running surface, piston, piston rings and lifting bearing journal lightly. z Clamp piston rings with piston ring tensioning band (1). Note Do not turn the piston rings any more. 1 © 39284 0 6 z Set lifting bearing journal in the lower dead point. 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.
Drive system W 02-09-03 2011 z Install the con rod bearing cover. 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. 1 © 39287 0 6 z 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.
Drive system W 02-09-07 2011 W 02-09-07 Check piston Tools References - Commercial tools Micrometer gauge Internal measuring device - W 02-09-03 - Special tools 100 400 - Meter Note If the wear limit is reached, the piston has to be changed. 6 Check the piston bolt bore z Remove piston from con rod. Î Job card W 02-09-03. © 39054 0 Prepare internal measuring device z Mount probe bolt for the appropriate measuring range in the internal measuring device. z Mount meter with approx.
Drive system W 02-09-07 2011 Note Schematic representation for measuring the piston bolt bore at the points ”a” and ”b” in the levels ”1” and ”2”. a b a b 1 2 © 37239 0 6 z Measure piston bolt bore with internal measuring device. Insert the internal measuring device in the piston bolt bush. z 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.
Drive system W 02-09-07 2011 z Measure piston diameter with micrometer gauge. Note Measuring points, see schematic diagram. 02 71 02 72 02 73 z Complete the con rod with piston Î Job card W 02-09-03.
Drive system W 02-09-07 2011 Notes 6 © 11/2004 4/4 0312 1571 - 0138
Drive system W 02-10-03 2011 W 02-10-03 Check piston rings and piston ring grooves Tools References - Commercial tools Feeler gauges - W 02-09-03 - Special tools 130 300 - Universal piston ring pliers 130 420 - Trapezoidal wear gauge 6 Check piston rings and piston ring grooves z Remove piston from con rod. Î Job card W 02-09-03. z Set universal piston ring pliers to the piston diameter. 02 71 z Remove piston rings with universal piston ring pliers.
Drive system W 02-10-03 2011 Only in BFL, BFM engines z Measure piston ring trapezoidal groove for first piston ring with trapezoidal groove wear gauge. © 33866 1 6 z If there is a gap (S) between the trapezoidal wear gauge and piston, the piston is still usable. S © 33867 1 z If the trapezoidal groove wear gauge is touching the piston (arrow), the piston must be changed.
Drive system W 02-10-03 2011 Check the piston ring joint clearance z Insert the piston ring (1) in the cylinder. Note Align the piston ring in the cylinder by pushing the piston. 1 © 39214 0 6 z Measure the piston ring joint clearance with a feeler gauge. Note If the wear limit is reached, change the piston ring. 02 84 02 85 02 86 © 39215 0 z Install piston rings. Note 1. 1. 2. 3. - Order and position of the piston rings seen from the piston base.
Drive system W 02-10-03 2011 z Install rings with universal piston ring pliers. Note Set spring joint of the roof chamfer ring 180° to the ring joint. © 39217 0 6 Check the piston ring axial clearance z 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.
Drive system W 02-15-01 2011 W 02-15-01 Remove and install piston cooling nozzles Tools References - Commercial tools - W 02-04-01 6 Remove piston cooling nozzles z Remove crankshaft Î Job card W 02-04-01. z Press out piston cooling nozzle (1) with a suitable tool (2). 1 2 © 39210 0 Install piston cooling nozzles z Clean bores for piston cooling nozzles in the crankcase. z Press in piston cooling nozzle (1) with suitable tool to the stop. z Install crankshaft Î Job card W 02-04-01.
Drive system W 02-15-01 2011 Notes 6 © 11/2004 2/2 0312 1573 - 0138
Crankcase W 03-01-11 2011 W 03-01-11 Remove and install crankcase bleeding Tools - Commercial tools 6 Remove bleed valve z Unscrew screw (1) and remove bleed valve (2). z Clean components and check for visible signs of wear. 1 2 © 39028 0 z Pull new round sealing ring (1) onto bleed valve (2).
Crankcase W 03-01-11 2011 Install bleed valve z Mount bleed valve (2) and press in. Note 1 The bleed valve must contact the front cover evenly. z Tighten screw (1). 2 03060 © 39028 0 6 In BFL, BFM engines Remove bleed valve z Unscrew screw (1) and remove bleed valve (2). z Clean components and check for visible signs of wear. 2 1 © 34038 1 z Pull new round sealing ring (1) onto bleed valve (2).
Crankcase W 03-01-11 2011 Install bleed valve z Mount bleed valve (1) and press in. Note The bleed valve must touch the cylinder head cover evenly. z Tighten screw.
Crankcase W 03-01-11 2011 Notes 6 © 11/2004 4/4 0312 1574 - 0138
Engine control W 04-03-01 2011 W 04-03-01 Renew camshaft sealing ring (opposite side to flywheel) Tools References - Commercial tools 9017 - Assembly lever - W 04-04-12 (old version) - W 04-04-12 (new version) - Special tools 142 050 - Press-in device 6 Remove camshaft sealing ring z Remove toothed belt and clamping roller, loosen camshaft toothed belt wheel Î Job card W 04-04-12(old version) Î Job card W 04-04-12(new version) 2 1 z Unscrew center screw (1) with washer (2) and remove the camshaft
Engine control W 04-03-01 2011 z Carefully drill a hole (at least 3 mm Ø) 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. © 39657 0 6 z Turn in self-tapping screw (1) with washer. 1 © 39658 0 z Pull out crankshaft sealing ring with assembly lever. z Visually inspect the running surface of the crankshaft flange and front cover.
Engine control W 04-03-01 2011 Install camshaft sealing ring z Oil the sealing lip of the new camshaft sealing ring lightly with engine oil. z 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 6 z Mount the camshaft sealing ring with the assembly tool and turn in the screw. © 39660 0 z Pull in the assembly tool to the stop by turning in the screw.
Engine control W 04-03-01 2011 z 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. z Install toothed belt and clamping roller, fix camshaft toothed belt wheel.
Crankcase W 03-03-01 2011 W 03-03-01 Check cylinder Tools Note - Commercial tools Internal measuring device Micrometer gauge - 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. - Special tools 100 400 - Meter References - W 01-04-04 6 z Remove cylinder head Î Job card W 01-04-04.
Crankcase W 03-03-01 2011 Note Schematic representation for measuring the cylinder running surface at the points ”a” and ”b” in the levels ”1 - 3". a b a b a b 1 2 3 © 39100 0 6 z Measure cylinder with internal measuring device. Insert internal measuring device in the cylinder. z 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.
Crankcase W 03-08-01 2011 W 03-08-01 Remove and install front cover (opposite side to flywheel) Tools Auxiliary material - Commercial tools 8036 - Socket 8049 - Force multiplier 8189 - Torx tool kit 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 - Special tools 142 850 - Assembly tool 143 420 - Holder 143 430 - Intermediate disc 6 Remove front cover z Remove toothed belt and clamping roller, loosen camshaft toothed belt wheel Î Job
Crankcase W 03-08-01 2011 z Mount holder. Note - The fixing bolts (1) must engage the bores (2). - Do not turn the crankshaft. 2 1 © 39375 0 6 z Tighten screws (1). Note Do not turn the crankshaft. 1 © 39293 0 z Mount force multiplier with socket. Note Snap in setting bolts (1) in ”CCW” position.
Crankcase W 03-08-01 2011 z Hold the force multiplier and loosen the center screw. z Remove the force multiplier, holder and intermediate disc. © 39460 0 6 z Unscrew center screw (1) and remove toothed wheel (2). Note An adapter is used in place of the toothed wheel without a hydraulic pump mounted. 2 1 © 39295 0 z Remove crankshaft toothed wheel (1). z Remove lube oil pump Î Job card W 08-04-05.
Crankcase W 03-08-01 2011 z Unscrew screws (1) and remove hydraulic pump console with hydraulic pump. 1 1 © 39297 0 6 z Unscrew screw (1) and remove cable plug (2) from engine shutdown. z Pull out cable plug (3) from lifting magnet for start volume release. 1 2 z Remove lube oil tray Î Job card W 08-08-02. 3 © 39298 0 z Unscrew screws (arrows) and remove front cover. z Check components for visible signs of damage.
Crankcase W 03-08-01 2011 Install front cover z Knock out crankshaft sealing ring (1). Note Do not damage the sealing surface when knocking out. z Clean the sealing surfaces on the front cover and crankcase. 1 © 39527 0 6 z Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. z Fit the crankshaft sealing ring (1) to the assembly sleeve(2). 1 2 Note The sealing lip must face the crankshaft in assembly. © 39515 0 z Drive in crankshaft sealing ring with assembly tool.
Crankcase W 03-08-01 2011 z Coat sealing surface of the front cover with sealant DEUTZ DW 67. Note The connection between the camshaft pin and the centrifugal force regulator must be clean and free of oil. z Turn engine 180°. Note The oil tray sealing surface on the crankcase must face up. © 34110 1 6 z Mount the front cover with shaft sealing ring and tighten the screws. z Align the front cover flush with the oil tray sealing surface (arrows).
Crankcase W 03-08-01 2011 z Plug the cable plug (2) to the engine shutdown and tighten the screw (1). z Plug the cable plug (3) to the lifting magnet for start volume release. 1 2 3 © 39298 0 6 z Clean the sealing surface on the hydraulic pump console and crankcase. z Insert new round sealing ring (arrow). © 39451 0 z Check all clamping sleeves are in place (arrows).
Crankcase W 03-08-01 2011 z Mount the hydraulic pump console and tighten the screws. Note Note different screw length: Screw M10 x 75 mm (1) Screws M10 x 90 mm (2) 2 1 2 © 39668 0 6 z Tighten screws (1). 12057 1 z Install lube oil pump Î Job card W 08-04-05. z Renew camshaft sealing ring Î Job card W 04-03-01. 1 © 39297 0 Install crankshaft toothed wheel z Mount crankshaft toothed wheel (1). Note All connections must be clean and oil free.
Crankcase W 03-08-01 2011 z Mount toothed wheel (1) for hydraulic pump. Note - An adapter is used in place of the toothed wheel without a hydraulic pump mounted. - All connections must be clean and oil free. 1 © 39454 0 6 z Tighten the center screw (1). Note Use new screw. 1 © 39455 0 z Pre-tighten center screw.
Crankcase W 03-08-01 2011 z Mount intermediate disc. Note The fixing bolts (1) must engage the bores (2). 1 2 1 © 39374 0 6 z Mount holder. Note - The fixing bolts (1) must engage the bores (2). - Do not turn the crankshaft. 2 1 © 39375 0 z Tighten screws (1). Note Do not turn the crankshaft.
Crankcase W 03-08-01 2011 z Mount force multiplier with socket. Note Snap in setting bolts (1) in ”CW” position. 1 © 39457 0 6 z Turn the ratchet (1) of the force multiplier to the stop (arrow). z Set scale dial (2) to "0". 2 1 © 39458 0 z Hold the force multiplier and tighten the center screw.
Crankcase W 03-08-01 2011 z Hold the force multiplier to counter (arrows), press setting bolts (1) and release force multiplier. Caution! ! Danger of injury when removing an unreleased force multiplier. z Remove the force multiplier with socket, holder and intermediate disc. 1 © 39669 0 6 Install camshaft toothed belt wheel z Mount camshaft toothed belt wheel (3) and tighten center screw (1) with washer (2).
Crankcase W 03-08-03 2011 W 03-08-03 Dismantle and complete front cover (Speed governor with torque adjustment) Tools References - Commercial tools Depth-measuring appliance - W 03-08-01 - Special tools 100 400 - Meter 100 750 - Measuring device 6 Note Distinguishing mark for a speed governor with torque adjustment: Adjustment capsule with clamping claw (1) in place of a full load volume stop. 1 © 39629 0 Dismantle front cover 1 z Remove front cover Î Job card W 03-08-01.
Crankcase W 03-08-03 2011 z Unscrew screws (1) and remove lifting magnet (2). 1 2 © 39262 0 6 z Unscrew screws (1) and remove cap (2) with gasket. 2 1 © 39263 0 z Unhook regulator spring (1).
Crankcase W 03-08-03 2011 z Unscrew nuts (1). z Remove controller lever shaft with roller lever (2) and adjustment lever (3). 2 1 3 © 39632 0 6 z Remove shims (1). Note Pay attention to number and arrangement. 1 1 © 39633 0 z Remove centrifugal force measuring mechanism (1).
Crankcase W 03-08-03 2011 z Unscrew nut (1) and remove clamping claw (2). z Unscrew idling capsule (3) and remove spring (4). 1 1 2 3 4 © 39637 0 6 z Unscrew nut (1) and remove clamping claw (2). 1 2 © 39635 0 z Unscrew adjustment capsule (1).
Crankcase W 03-08-03 2011 For speed governor with minus adjustment z Remove locking ring (1) and deflector lever (2). 2 1 © 39269 0 6 z Unscrew lifting magnet for start volume release (1). 1 © 39270 0 z Remove locking ring (1). z Pull out actuating lever (2), remove spring and washer.
Crankcase W 03-08-03 2011 z Unhook spring from stop (arrow). © 39529 0 6 z Knock out clamping pin (1), remove shutoff lever (2) and disc. 1 2 © 39528 0 z Remove guide bush (1) and round sealing ring (2). z Pull out shutoff shaft (3).
Crankcase W 03-08-03 2011 For speed governor with minus adjustment z Unscrew nut (1) and remove washer. 1 © 39272 0 6 z Knock out clamping pin (1). Note Mark the installation position of the eccenter shaft (2) before removing. 1 2 © 39467 0 z Pull out eccenter shaft (1). Remove guide bush (2) and round sealing ring (3).
Crankcase W 03-08-03 2011 z Remove locking bolt (arrow). Note Do not damage the sealing surface on the front cover. © 33928 1 6 z Knock out clamping pin (1). Note Do not jam the clamping pin in the cover when knocking out. 1 © 39470 0 z Insert the speed adjustment lever (1) with shaft, guide bush and round sealing ring. 1 z Remove adjustment lever (2).
Crankcase W 03-08-03 2011 z Unscrew lock nut (1) and turn out setting screw for minimum speed (2). z Check components for visible signs of damage. 2 1 © 39274 0 6 Complete front cover z Turn in setting screw for minimum speed (2) and put on lock nut (1). 2 1 © 39274 0 z Set setting screw (1) for minimum speed to dimension "X". X 05 05 2 Note The setting dimension ”X” only serves as a basic setting. A test stand run is necessary for the performance and speed setting. 1 z Tighten lock nut (2).
Crankcase W 03-08-03 2011 z Insert the speed adjustment lever (1) with shaft, guide bush and new round sealing ring. Note Oil the speed adjustment shaft lightly. 1 © 39469 0 6 z Insert adjustment lever (1) with clamping pin. Note Note the installation position, the hole for hooking in the regulator spring (arrow) must face the outside of the front cover. z Press the speed adjustment shaft (2) into the front cover to the stop.
Crankcase W 03-08-03 2011 z Knock in the locking bolt (arrow) to the stop. Note The groove in the speed adjustment shaft must match up with the bore in the front cover. © 33960 1 6 For speed governor with minus adjustment z Oil lightly and insert the eccenter shaft (1). 1 © 39471 0 z Drive in clamping pin (1) flush with the front cover. Note The groove in the eccenter shaft must match up with the bore for he clamping pin.
Crankcase W 03-08-03 2011 z Put on new round sealing ring (1) and guide bush (2). Note Oil round sealing ring lightly. 1 2 © 39472 0 6 z Fit washer and tighten nut (1). z Position the eccenter shaft at the mark made before removal. z Tighten nut (1). 05024 1 © 39272 0 z Insert shutoff shaft, pre-tension spring (1) and hang into stop (arrow). Note 1 - Note installation position. - Oil the shutoff shaft lightly.
Crankcase W 03-08-03 2011 z Put on new round sealing ring (1) and guide bush (2). Note Oil round sealing ring lightly. 1 2 © 39474 0 6 z Press the shutoff shaft into the front cover inlet. z Put on washer (1) and shutoff lever (2) with clamping pin. Note Note installation position of the shutoff lever. 2 1 © 39475 0 z Drive in clamping pin (arrow) flush with the shutoff lever. Note The bore in the shutoff shaft must match up with the bore in the shutoff lever.
Crankcase W 03-08-03 2011 For speed governor with minus adjustment z Insert actuating lever (1), spring and washer. Note Note installation position of the actuating lever. 1 © 39476 0 6 z Put on locking ring (1). Note Pay attention to correct fit of the locking ring in the groove. 1 © 39464 0 z Tighten lifting magnet for start volume release (1) with new round sealing ring.
Crankcase W 03-08-03 2011 z Remove deflector lever (2) and locking ring (1). Note - Note installation position of the deflector lever. - Pay attention to correct fit of the locking ring in the groove. 2 1 © 39269 0 6 z Insert centrifugal force measuring mechanism (1). Note Do not damage the sealing lip of the shaft sealing ring. 1 © 39634 0 Measure and set the parallelism of the roller lever. z Place shim discs of at least 0.3 mm on the stud bolts (1).
Crankcase W 03-08-03 2011 z Insert regulator lever shaft with roller lever (1) and tighten nuts (2). 2 1 05021 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.
Crankcase W 03-08-03 2011 z Move the measuring bridge and position the stylus on the ball bearing (1). z 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 © 39280 0 6 z Compensate the tolerance by using shim discs (1) of suitable thickness. z Repeat the measuring process after setting. 1 1 © 39633 0 z Unscrew nuts and remove regulator lever shaft.
Crankcase W 03-08-03 2011 z Remove regulator lever shaft with roller lever (2) and adjustment lever (3). 2 z Tighten nuts (1). 05021 Note Note installation position of the regulator lever shaft. 1 3 © 39632 0 6 z Hook in regulator spring (1). 1 © 39631 0 z Visually inspect the components of the adjustment capsule, renew if necessary.
Crankcase W 03-08-03 2011 Pre-assemble the adjustment capsule z Turn in the spring pre-tensioner (1) to the stop in the housing (2) with max. 1 Nm. z Turn out the spring pre-tensioner 1 + 0.5 turns again. 1 2 3 z Tighten lock nut (3). 05006 © 33941 0 6 z Turn in setting screw (2) to the stop on the pressure capsule (1). z Turn out the setting screw 1 turn again. z Tighten lock nut (3). 1 05008 2 3 © 33942 1 z Fit new round sealing ring (arrow) onto adjustment capsule.
Crankcase W 03-08-03 2011 z Screw in adjustment capsule (1). 1 © 39636 0 6 z Measure screw-in depth "X" of the adjustment capsule with depth measuring appliance from the front cover to the housing. X 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 z Insert clamping claw (2) and tighten nut (1).
Crankcase W 03-08-03 2011 z Fit new round sealing ring (arrow) onto idling. Note Oil round sealing ring lightly. © 39477 0 6 z Insert spring (1) and turn in idling capsule (2) flush with the inside edge of the front cover (arrow). 2 1 © 34002 1 z Insert clamping claw (1) and tighten nut (2). Note Note installation position of the clamping claw.
Crankcase W 03-08-03 2011 z Mount cover (2) with new gasket and tighten screws (1). 05025 2 1 © 39263 0 6 z Pull new round sealing ring (1) onto lifting magnet. 1 © 39036 0 z Insert lifting magnet (2) and tighten screws (1).
Crankcase W 03-08-03 2011 z Pull new round sealing ring (1) onto bleed valve (2). 2 1 © 39029 0 6 z Mount bleed valve (2) and press in. 1 Note The bleed valve must contact the front cover evenly. z Tighten screw (1). 2 03060 z Install front cover Î Job card W 03-08-01.
Crankcase W 03-08-03 2011 Notes 6 © 11/2004 24/24 0312 1577 - 0138
Crankcase W 03-08-03 2011 W 03-08-03 Dismantle and complete front cover (Speed governor without torque adjustment) Tools References - Commercial tools Depth-measuring appliance - W 03-08-01 - Special tools 100 400 - Meter 100 750 - Measuring device 6 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 1 z Remove front cover Î Job card W 03-08-01.
Crankcase W 03-08-03 2011 z Unscrew screws (1) and remove lfiting magnet (2). 2 1 © 33914 1 6 z Unscrew screws (1) and remove cap (arrow) with gasket. 1 1 © 33926 1 z Unhook regulator spring (1).
Crankcase W 03-08-03 2011 z Unscrew nuts (arrows). z Remove controller lever shaft with roller lever (1) and adjustment lever (2). 1 2 © 33916 1 6 z Remove shim discs (arrow). Note Pay attention to number and arrangement. © 33917 1 z Remove centrifugal force measuring mechanism (1).
Crankcase W 03-08-03 2011 z Unscrew nut (1) and remove clamping claw (2). z Unscrew idling capsule (3) and remove (4) spring. 1 1 2 3 4 © 39637 0 6 z Unhook spring from stop (arrow). © 33921 1 z Drive out clamping pin.
Crankcase W 03-08-03 2011 z Remove shutoff lever (1) and guide bush. 1 © 33923 1 6 z Pull out shutoff shaft (1) with spacing bush and spring. 1 © 33924 1 z Remove round sealing ring (arrow).
Crankcase W 03-08-03 2011 z Knock out clamping pin (1). 1 © 33927 1 6 z Remove locking bolt (arrow). Note Do not damage the sealing surface on the front cover. © 33928 1 z Pull out the speed adjustment lever (1) with shaft and guide bush, remove the adjustment lever (2).
Crankcase W 03-08-03 2011 z Remove round sealing ring (arrow). 1 © 33930 1 6 z Loosen lock nut (arrows). z Unscrew setting screw for shutoff stop (1), full load stop (2) and minimum speed (3). 1 z Check components for visible signs of damage. 2 3 © 39203 0 Complete front cover z 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. z Screw on lock nuts.
Crankcase W 03-08-03 2011 z Set setting screw (1) for full load stop to dimension "X". 2 1 05 04 z Tighten lock nut (2). 05004 x © 33939 1 6 z Screw in setting screw (1) for shutoff stop so that the lock nut is flush with the end of the bolt (arrows). z Tighten lock nut. 05007 1 © 33949 1 z Set setting screw (1) for minimum speed to dimension "X". X 05 05 2 Note The setting dimension ”X” only serves as a basic setting. A test stand run is necessary for the performance and speed setting.
Crankcase W 03-08-03 2011 z Push the spacer bush (arrow) and spring onto the shutoff shaft. © 33951 1 6 z Insert shutoff shaft and hook in spring. Note - Note installation position. - Oil the shutoff shaft lightly. © 33952 1 z Insert new round sealing ring (1). Note Oil round sealing ring lightly.
Crankcase W 03-08-03 2011 z Insert guide bush (1). 1 © 33954 1 6 z Press the shutoff shaft into the front cover to the stop. z Push on shutoff lever with clamping pin. Note Note installation position of the shutoff lever. © 33955 1 z Drive in clamping pin flush with the shutoff lever. Note The bore in the shutoff shaft must match up with the bore in the shutoff lever.
Crankcase W 03-08-03 2011 z Insert new round sealing ring (1). Note Oil round sealing ring lightly. 1 © 33956 1 6 z 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. 2 1 © 33957 1 z Insert adjustment lever (1) with clamping pin. Note 2 Note the installation position, the hole for hooking in the regulator spring (arrow) must face the outside of the front cover.
Crankcase W 03-08-03 2011 z Drive in clamping pin (1) flush with the adjustment lever. Note The bore in the speed adjustment shaft must match up with the bore in the adjustment lever. 1 © 33959 1 6 z Knock in the locking bolt (arrow) to the stop. Note The groove in the speed adjustment shaft must match up with the bore in the front cover. © 33960 1 z Insert centrifugal force measuring mechanism (1). Note Do not damage the sealing lip of the shaft sealing ring.
Crankcase W 03-08-03 2011 Measure and set the parallelism of the roller lever. z Place shim discs of at least 0.3 mm on the stud bolts (1). 1 1 © 33963 1 6 z Insert regulator lever shaft with roller lever (1) and tighten nuts (2). 2 1 05021 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.
Crankcase W 03-08-03 2011 z Insert meter in measuring bridge and position the stylus with pre-tension on the ball bearing (1). z Adjust meter to "0". 1 © 33965 1 6 z Move the measuring bridge and position the stylus on the ball bearing (1). z 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.
Crankcase W 03-08-03 2011 z Unscrew nuts and remove regulator lever shaft. z Push the adjustment lever (1) onto the regulator lever shaft (2). Note Note installation position of the adjustment lever. 2 1 © 33967 1 6 z Insert regulator lever shaft with roller lever and adjustment lever. z Tighten nuts. 05021 Note Note installation position of the regulator lever shaft. © 33968 1 z Hook in regulator spring (1).
Crankcase W 03-08-03 2011 z Fit new round sealing ring (arrow) onto idling capsule. Note Oil round sealing ring lightly. © 39477 0 6 z Insert spring (1) and turn in idling capsule (2) flush with the inside edge of the front cover (arrow). 2 1 © 34002 1 z Insert clamping claw (1) and tighten nut (2). Note Note installation position of the clamping claw.
Crankcase W 03-08-03 2011 z Mount cover (1) with new gasket and tighten screws (2). 05025 1 2 2 © 33970 1 6 z Pull new round sealing ring (1) onto lifting magnet. 1 © 33971 1 z Insert lifting magnet and tighten screws. Note Note installation position of the lifting magnet.
Crankcase W 03-08-03 2011 z Pull new round sealing ring (1) onto bleed valve. 2 1 © 39029 0 6 z Mount bleed valve (1) and press in. Note The bleed valve must contact the front cover evenly. z Tighten screw. 1 03060 z Install front cover Î Job card W 03-08-01.
Crankcase W 03-09-01 2011 W 03-09-01 Remove and install rear cover (flywheel side) Tools References - Commercial tools - W 03-09-04 - W 08-04-07 - Special tools 142 860 - Assembly tool Auxiliary material - DEUTZ DW 67 6 Remove rear cover (flywheel side) z Remove connection housing Î Job card W 03-09-04. 1 z Remove oil tray Î Job card W 08-04-07. z Unscrew screws (arrows) and remove rear cover (1). © 39031 0 Renew crankshaft sealing ring z Knock out crankshaft sealing ring (1).
Crankcase W 03-09-01 2011 z Oil the sealing lip of the new crankshaft sealing ring lightly with engine oil. z 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 6 Note Installation depth X = approx. 2.5 mm of the crankshaft sealing ring. X © 39352 0 z Press in crankshaft sealing ring with assembly tool. Note - Note installation depth.
Crankcase W 03-09-01 2011 Install rear cover (flywheel side) z Clean the sealing surface on the rear cover and crankcase. z Apply sealant DEUTZ DW 67 to rear cover. © 34100 1 6 z 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. z Align the rear cover to the sealing surface of the oil tray (arrows).
Crankcase W 03-09-01 2011 Notes 6 © 11/2004 4/4 0312 1579 - 0138
Crankcase W 03-09-04 2011 W 03-09-04 Remove and install connection housing Tools References - Commercial tools - W 00-05-01 - W 12-06-01 6 Remove connection housing z Mount engine on engine assembly stand Î Job card W 00-05-01. z Remove flywheel Î Job card W 12-06-01. z Unscrew screws (1) and remove engine mounting (2). 2 2 1 1 © 39041 0 z Unscrew screws (arrows) and remove connection housing.
Crankcase W 03-09-04 2011 Install connection housing z Clean contact surfaces on connection housing and crankcase. © 39048 1 6 Note Make sure the clamping sleeves (arrows) are in place. z Knock clamping sleeves into the crankcase to the stop. z Mount the connection housing and center over the clamping sleeves. © 39049 0 z Tighten screws (arrows) alternately.
Crankcase W 03-09-04 2011 z Mount engine bearing (2) and tighten screws (1). 00003 Note Note installation position. z Install flywheel. Î Job card W 12-06-01.
Crankcase W 03-09-04 2011 Notes 6 © 11/2004 4/4 0312 1580 - 0138
Crankcase W 03-11-01 2011 W 03-11-01 Remove and install camshaft bearing, check Tools References - Commercial tools - W 01-02-02 - W 02-04-01 - W 07-04-01(Motorpal) - W 07-04-01(Bosch) - W 07-11-01 - Special tools 100 700 - Setting bolt 143 820 - Assembly tool 6 Remove camshaft z Remove crankshaft Î Job card W 02-04-01. z Remove toggle lever and toggle lever blocks Î Job card W 01-02-02.
Crankcase W 03-11-01 2011 z Press in all tappets. z Pull out camshaft (1) carefully to the flywheel side. 1 © 39303 0 6 Check the camshaft bearing. Prepare internal measuring device z Mount probe bolt for the appropriate measuring range in the internal measuring device. z Mount meter with approx. 1 mm pre-tension in the internal measuring device. z Set micrometer gauge to 54 mm.
Crankcase W 03-11-01 2011 z Measure camshaft bearing with internal measuring device. Insert internal measuring device in the camshaft bearing. z 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. - If the wear limit is reached, the bearing has to be changed. 03 13 03 14 © 39304 0 6 Remove camshaft bearing z Remove all tappets (arrow).
Crankcase W 03-11-01 2011 z Push in spindle, push on holder (1) and insert in inside camshaft bearing. Note Make sure that the holder is evenly in contact with the crankcase. 1 z Fit washer and nut. © 39307 0 6 z Press out outer camshaft bearing. z Dismantle assembly tool and remove camshaft bearing. © 39308 0 Remove inner camshaft bearing z Insert extraction bush (1) in inner camshaft bearings. 1 z Insert spindle and fit washer and nut.
Crankcase W 03-11-01 2011 z Pull out inner camshaft bearing. z Dismantle assembly tool and remove camshaft bearing. © 39310 0 6 Install camshaft bearing 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 4-cylinder A = flywheel side B = opposite side to flywheel 2.5 ± 0.3 mm 0.5 ± 0.3 mm 117.1 ± 0.3 mm 2.5 ± 0.3 mm 118.9 ± 0.3 mm 0.5 ± 0.3 mm 117.
Crankcase W 03-11-01 2011 Install inner camshaft bearing z Mount inner camshaft bearing. Note - Note position of joint (1), see schematic diagram. - Check that the oil bores (arrows) in the camshaft bearing and the crankcase match up. 1 © 39312 0 6 z Insert extraction bush (1) in the inner camshaft bearing. z Insert spindle and fit washer and nut. Note - Do not change the installation position of the camshaft bearing. - Counterbearing centered to bearing bore.
Crankcase W 03-11-01 2011 z 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. z Remove the assembly tool. © 39315 0 6 Install outer camshaft bearing z Mount outer camshaft bearing. 2 Note - Note position of joint (1), see schematic diagram.
Crankcase W 03-11-01 2011 z Pull in the camshaft bearing. z Loosen assembly tool. z 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. © 39317 0 6 z 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.
Crankcase W 03-11-01 2011 Install camshaft z Oil camshaft bearing and camshaft journal lightly. Note The connecting surface (arrow) with the muff of the measuring mechanism must be clean and oil free. © 39252 0 6 z Insert camshaft carefully. Note Check that the bores (1) in the camshaft and the crankcase match up. 1 1 © 39319 0 z Fit startup disc (1) and tighten screw. Note The lubricating groove (2) of the startup disc must face the crankcase.
Crankcase W 03-11-01 2011 z Turn in the setting bolt (1), for locking the camshaft, to the stop in the crankcase. z Tighten screw. 04002 1 © 39321 0 6 z Install crankshaft Î Job card W 02-04-01. z Install toggle lever and toggle lever blocks Î Job card W 01-02-02. z Install fuel pump Î Job card W 07-11-01. z Install injection pumps.
Engine control W 04-04-11 2011 W 04-04-11 Check engine control times Tools References - Commercial tools - W 04-04-12 (old version) - W 04-04-12 (new version) - Special tools 100 700 - Setting bolt Caution! ! It is not permissible to retighten a toothed belt which has already been in operation and to set the engine control times. 6 Check engine control times Lock camshaft. z Unscrew cap (1) and remove sealing ring. 1 © 39670 0 z Insert setting bolt (1) in the bore (2) to lock the camshaft.
Engine control W 04-04-11 2011 z 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 6 z Screw setting bolts (1) into the crankcase. 1 © 39186 0 z Unscrew cap (1) and remove sealing ring.
Engine control W 04-04-11 2011 z 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 6 z 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. z Make help marks (arrow) on the crankcase and setting bolt.
Engine control W 04-04-11 2011 z Tighten locking screw (1) with new CU sealing ring. 03003 1 © 39670 0 6 z Tighten locking screw (1) with new CU sealing ring.
Engine control W 04-04-12 2011 W 04-04-12 Renew toothed belt and clamping roller (old version of the clamping roller) Tools References - Commercial tools 8189 - Torx tool kit 9120 - Special bit, 70 mm long 9122 - Special bit, 25 mm long - W 12-02-01 (FL, BFL engines) - W 12-02-01 (FM, BFM engines) - W 12-08-03 Caution! ! - Special tools 100 700 - Setting bolt 144 130 - Holder The toothed belt and the clamping roller must be renewed after every disassembly regardless of their time in operation.
Engine control W 04-04-12 2011 z Unscrew screws (1), flange hub (2) and remove V-belt pulley. 1 2 1 © 39461 0 6 z Unscrew screws (1) and remove V-belt pulley (2). Note Hold at the center screw. 2 1 1 © 39354 0 z Remove centrifugal disc (1). z Remove toothed belt and clamping roller of the hydraulic pump Î Job card W 12-08-03.
Engine control W 04-04-12 2011 In FL, BFL engines z Unscrew screws (1) and remove V-belt clamping roller (2). 1 2 © 39356 0 6 z Unscrew locking screw (1). Note Use a special bit, 70 mm long. z Unscrew screws (2) and remove protective cover (1). 2 1 3 © 39357 0 z Unscrew screws (1) and remove protective cover (2).
Engine control W 04-04-12 2011 Lock camshaft z Unscrew cap (1) and remove sealing ring. 1 © 39670 0 6 z Insert setting bolt (1) in the bore (2) to lock the camshaft. 1 2 © 39671 0 z 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.
Engine control W 04-04-12 2011 z Screw setting bolt (1) into the crankcase to the stop. 1 © 39186 0 6 Lock the crankshaft z Unscrew cap (1) and remove sealing ring. 1 © 39187 0 z Insert setting bolt (1) in the bore (2) to lock the crankshaft.
Engine control W 04-04-12 2011 z Screw setting bolts (1) into the crankcase. Note The cylinder at the front cover is now in the ignition UT. 1 © 39188 0 6 z Unscrew screw (1) and remove clamping roller (2). z Remove toothed belt (3). 3 1 2 © 34054 1 Loosen camshaft toothed belt wheel z Mount holder (1) and loosen center screw (2). Note Do not turn the camshaft.
Engine control W 04-04-12 2011 Install toothed belt and clamping roller z 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. 1 © 39360 0 6 z Turn the crankshaft carefully in the direction of rotation of the engine (clockwise) until it touches the setting bolts. © 39130 0 z Mount new toothed belt.
Engine control W 04-04-12 2011 z Insert new clamping roller with the guide fork (1) of the base plate in the guide pin (2) of the front cover. 3 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 1 z Screw in screw (3). 2 © 39362 0 6 z Position setting eccenter (arrow) in 6:00 h position. z Press the clamping roller against the toothed belt and pre-tighten the screw (1).
Engine control W 04-04-12 2011 z 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. 1 © 39364 0 6 z Remove locking pin (1).
Engine control W 04-04-12 2011 Fix the camshaft toothed belt wheel z Mount holder (1) and pre-tighten center screw (2). z Tighten center screw (2). 04001 2 1 Note - Hold the toothed belt wheel. - Hold the crankshaft against the stop. © 34135 1 6 Check the toothed belt tension z Unscrew the setting bolts for camshaft and crankshaft locking. z Make help marks on the camshaft toothed belt wheel and the screw opposite (arrow).
Engine control W 04-04-12 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. 1 © 34140 1 6 Correct the toothed belt tension z Loosen screw and re-tighten. 04052 z 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). 1 z Tighten screw. 04052 © 34134 1 Check engine control times Lock camshaft.
Engine control W 04-04-12 2011 z 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 6 z 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. z Make help marks (arrow) on the crankcase and setting bolt.
Engine control W 04-04-12 2011 z Tighten locking screw (1) with new CU sealing ring. 03003 1 © 39670 0 6 z Tighten locking screw (1) with new CU sealing ring. 03003 1 © 39187 0 z Inspect the protective covers visually, renew the sealing profile if necessary.
Engine control W 04-04-12 2011 z Mount protective cover (2) and tighten screws (1). Note Pay attention to the correct fitting of the protective cover. 1 2 04053 1 © 39358 0 6 z Mount protective cover (3) and tighten screws (2) . z Screw in locking screw (1). Note Use a special bit, 70 mm long. 2 z Tighten screws. 04053 1 3 © 39357 0 z Install toothed belt and clamping roller of the hydraulic pump Î Job card W 12-08-03. z Mount centrifugal disc (1).
Engine control W 04-04-12 2011 z Fit V-belt pulley (1) and tighten screws (2) alternately. Note 1 Hold at the center screw. 2 12031 2 © 39599 0 6 In FM, BFM engines z If available, mount V-belt pulley and flange hub (1). z Tighten (2) screws alternately. 2 12031 1 2 © 39462 0 z Mount fan and disc, tighten screws (1).
Engine control W 04-04-12 2011 In FL, BFL engines z Fit V-belt clamping roller (2) and tighten screws (1). z Install V-belt Î Job card W 12-02-01 (FL, BFL engines) Î Job card W 12-02-01 (FM, BFM engines).
Engine control W 04-04-12 2011 W 04-04-12 Renew toothed belt and clamping roller (new version of the clamping roller) Tools References - Commercial tools 8189 - Torx tool kit 9120 - Special bit, 70 mm long 9122 - Special bit, 25 mm long - W 12-02-01 (FL, BFL engines) - W 12-02-01 (FM, BFM engines) - W 12-08-03 Caution! ! - Special tools 100 700 - Setting bolt 144 130 - Holder The toothed belt and the clamping roller must be renewed after every disassembly regardless of their time in operation.
Engine control W 04-04-12 2011 z Unscrew screws (1) and remove flange hub (2) and V-belt pulley. 1 2 1 © 39461 0 6 z Unscrew screws (1) and remove V-belt pulley (2). Note Hold at the center screw. 2 1 1 © 39354 0 z Remove centrifugal disc (1). z Remove toothed belt and clamping roller of the hydraulic pump Î Job card W 12-08-03.
Engine control W 04-04-12 2011 In FL, BFL engines z Unscrew screws (1) and remove V-belt clamping roller (2). 1 2 © 39356 0 6 z Unscrew locking screw (1). Note Use a special bit, 70 mm long. z Unscrew screws (2) and remove protective cover (1). 2 1 3 © 39357 0 z Unscrew screws (1) and remove protective cover (2).
Engine control W 04-04-12 2011 Lock camshaft z Unscrew cap (1) and remove sealing ring. 1 © 39670 0 6 z Insert setting bolt (1) in the bore (2) to lock the camshaft. 1 2 © 39671 0 z 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.
Engine control W 04-04-12 2011 z Screw setting bolts (1) into the crankcase to the stop. 1 © 39186 0 6 Lock the crankshaft z Unscrew cap (1) and remove sealing ring. 1 © 39187 0 z Insert setting bolt (1) in the bore (2) to lock the crankshaft.
Engine control W 04-04-12 2011 z Screw setting bolts (1) into the crankcase. Note The cylinder at the front cover is now in the ignition UT. 1 © 39188 0 6 z Unscrew screw (1) and remove clamping roller (2). z Remove toothed belt (3). 3 1 2 © 39602 0 Loosen camshaft toothed belt wheel (without torsional vibration damper) z Mount holder (1) and loosen center screw (2). Note 2 Do not turn the camshaft.
Engine control W 04-04-12 2011 Loosen camshaft toothed belt wheel (with torsional vibration damper) Note 1 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). 2 © 39513 0 6 z Hold camshaft toothed belt wheel and loosen the center screw (1). Note 1 Do not turn the camshaft. © 39673 0 Install toothed belt and clamping roller z Tighten the center screw (1) hand tight.
Engine control W 04-04-12 2011 z Turn the crankshaft carefully in the direction of rotation of the engine (clockwise) until it touches the setting bolts. © 39130 0 6 z Mount new toothed belt. Note 1 Note the running direction of the toothed belt, the arrows (1) must point in the direction of rotation of the engine (arrow). © 39361 0 z Mount new clamping roller (1) and position setting eccenter (arrow) at 6.00 h position.
Engine control W 04-04-12 2011 z Press the clamping roller against the toothed belt and pre-tighten the screw. 04052 1 © 39604 0 6 z 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 z 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.
Engine control W 04-04-12 2011 z Turn setting eccenter in direction of arrow (counterclockwise) until the bores (1) in the setting eccenter are in line. Note Turn the setting eccenter at the hexagon socket. 1 z Tighten screw (2). 2 04052 © 39605 0 6 Fix the camshaft toothed belt wheel (without torsional vibration damper) z Mount holder (1) and pre-tighten center screw (2). z Tighten center screw (2). 2 1 Note - Hold the toothed belt wheel. - Hold the crankshaft against the stop.
Engine control W 04-04-12 2011 Check the toothed belt tension z Unscrew the setting bolts for camshaft and crankshaft locking. z Make help marks on the camshaft toothed belt wheel and insert the screw opposite (1). 1 z Turn the crankshaft 2 turns in the direction of rotation of the engine (clockwise) until the help marks are in line. © 39607 0 6 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.
Engine control W 04-04-12 2011 Check engine control times Lock camshaft z Insert setting bolt (1) for the camshaft lock in the bore and hold lightly. z Turn the crankshaft in the direction of rotation of the engine (clockwise) until the setting bolt engages the bore of the camshaft. z Screw setting bolt into the crankcase to the stop. 1 © 39186 0 6 z Tighten center screw with the torque wrench in engine direction of rotation with 40 Nm. Carefully relieve pressure on the torque wrench.
Engine control W 04-04-12 2011 z 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. X z Unscrew the setting bolts for camshaft and crankshaft locking. © 39543 0 6 z Tighten locking screw (1) with new CU sealing ring. 03003 1 © 39670 0 z Tighten locking screw (1) with new CU sealing ring.
Engine control W 04-04-12 2011 z Inspect the protective covers visually, renew the sealing profile if necessary. © 34229 1 6 z Mount protective cover (2) and tighten screws (1). Note Pay attention to the correct fitting of the protective cover. 1 2 04053 1 © 39358 0 z Mount protective cover (3) and tighten screws (2). z Screw in locking screw (1). Note Use a special bit, 70 mm long. z Tighten screws.
Engine control W 04-04-12 2011 z Install toothed belt and clamping roller of the hydraulic pump Î Job card W 12-08-03. z Mount centrifugal disc (1). Note The hollow throat must face the adapter. 1 © 39598 0 6 z Fit V-belt pulley (1) and tighten screws (2) alternately. Note 1 Hold at the center screw. 2 12031 2 © 39599 0 In FM, BFM engines (as an overview) z If available, mount the V-belt pulley and flange hub (1). z Tighten (2) screws alternately.
Engine control W 04-04-12 2011 z Mount fan and disc, tighten screws (1). 12031 1 1 © 39624 0 6 In FL, BFL engines z Fit V-belt clamping roller (2) and tighten screws (1).
Engine control W 04-05-05 2011 W 04-05-05 Remove and install camshaft Tools References - Commercial tools - 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 - Special tools - 100 700 - Setting bolt 6 Remove camshaft z Remove toothed belt and clamping roller and loosen camshaft toothed belt wheel Î Job card W 04-04-12 (old version) Î Job card W 04-04-12 (new version) 2 1 z Unscrew center screw (1) with washer (2)
Engine control W 04-05-05 2011 z Unscrew screw (1) and remove startup disc (2). z Unscrew setting bolts (3). 3 1 2 © 39246 0 6 z Press in all tappets. z Pull out camshaft (1) carefully to the flywheel side. 1 © 39242 0 Remove tappets. z Remove all tappets (arrow). Note Put down the components in the order of installation, note order of cylinders. z Check the tappets for visible signs of wear.
Engine control W 04-05-05 2011 Install tappets z Oil all tappets (arrow) lightly with engine oil and insert. Note Note assignment. © 39247 0 6 Install camshaft z 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 z Insert camshaft carefully. Note - The muff of the measuring mechanism must engage the front camshaft journal.
Engine control W 04-05-05 2011 z Fit startup disc (1) and tighten screw. Note The lubricating groove (2) of the startup disc must face the crankcase. 1 2 © 39254 0 6 z Screw setting bolts (1) into the crankcase to the stop. z Tighten screw. 04002 1 © 39255 0 z 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.
Engine control W 04-05-05 2011 z Install toggle lever and toggle lever blocks Î Job card W 01-02-02. z Install injection pumps. Î Job card W 07-04-01 (Motorpal) Î Job card W 07-04-01 (Bosch) z Install fuel pump Î Job card W 07-11-01. z Install rear cover (flywheel side) Î Job card W 03-09-01.
Engine control W 04-05-05 2011 Notes 6 © 11/2004 6/6 0312 1586 - 0138
Engine control W 04-05-06 2011 W 04-05-06 Check camshaft Tools References - Commercial tools - W 04-05-05 6 Check camshaft z Remove camshaft Î Job card W 04-05-05. z Visually inspect cam and bearing pin for wear, renew camshaft if necessary. z Install camshaft Î Job card W 04-05-05.
Engine control W 04-05-06 2011 Notes 6 © 11/2004 2/2 0312 1587 - 0138
Speed governing W 05-07-01 2011 W 05-07-01 Remove and install speed governor Tools - Commercial tools 6 Remove speed governor z Pull cable plug (1) out of speed governor (2). z Unscrew screw (3) and remove speed governor. 1 3 2 © 36789 1 Install speed governor z Fit new round sealing ring (arrow) onto speed governor.
Speed governing W 05-07-01 2011 z Insert speed governor (2) and tighten screw (3). 05011 z Plug cable plug (1) to speed governor.
Exhaust system / Charging W 06-01-05 2011 W 06-01-05 Remove and install exhaust manifold Tools References - Commercial tools 8189 - Torx tool kit - W 06-06-04 Auxiliary material - DEUTZ S1 6 In BF engines z Remove turbocharger (1). Î Job card W 06-06-04. 1 © 39071 0 Remove exhaust manifold z Unscrew screws (arrows), remove exhaust manifold (1) and gaskets. 1 z Check components for visible signs of damage.
Exhaust system / Charging W 06-01-05 2011 Install exhaust manifold z Clean the sealing surface on the exhaust manifold and cylinder head. Note Note installation position of the gaskets (1). 1 © 39223 0 6 z Mount exhaust manifold with new gaskets and tighten screws. Note Coat screws with assembly aid DEUTZ S1. zTighten screws alternately from the center outwards. 06001 © 39224 0 In BF engines z Install turbocharger (1). Î Job card W 06-06-04.
Exhaust system / Charging W 06-06-04 2011 W 06-06-04 Remove and install turbocharger Tools Note - Commercial tools 9090 - Clamping pliers Collect drained operating materials in suitable vessels and dispose of according to regulations. Auxiliary material - DEUTZ S1 6 Remove turbocharger z If available, remove the bleed pipe (1) and reducer (2). Unscrew screws (3). 3 z Loosen pipe clip (4), remove reducer with bleed pipe. 1 3 2 4 © 39394 0 z Unscrew screw (1) and remove holder.
Exhaust system / Charging W 06-06-04 2011 z Pull oil return line (1) out of the crankcase and pull off from oil return pipe flange support (2). 2 1 © 39396 0 6 z Unscrew hollow screws (1), remove oil pressure line (2) and sealing rings. 2 1 1 © 39397 0 z Unscrew screws (1), remove oil return pipe flange support (2) and gasket.
Exhaust system / Charging W 06-06-04 2011 z Loosen pipe clip (1) with clamping pliers. 1 © 39376 0 6 z Unscrew nuts (1), remove turbocharger (2) and gasket. 1 z Check components for visible signs of damage. 2 © 39377 0 Install turbocharger z Clean the sealing surface of the turbocharger and exhaust manifold. 1 z Mount turbocharger (2) with new gasket and tighten nuts (1). Note Coat pin bolts with assembly aid DEUTZ S1.
Exhaust system / Charging W 06-06-04 2011 z Position pipe clip (1) with clamping pliers. 1 © 39376 0 6 z Clean the sealing surface of the turbocharger and oil return pipe flange support. z Mount oil return pipe flange support (1) with new gasket and tighten screws (2). 1 08044 © 39627 0 z Pull new round sealing ring (arrow) onto oil return pipe flange support.
Exhaust system / Charging W 06-06-04 2011 z Mount oil pressure line (2), tighten hollow screws (1) with new CU sealing rings. 2 08042 1 1 © 39397 0 6 z Fit new round sealing ring (arrow) onto oil return pipe. © 39378 0 z Push oil return pipe (1) onto oil return pipe flange support (2) and insert in crankcase. Note Oil round sealing rings lightly.
Exhaust system / Charging W 06-06-04 2011 z Mount holder and tighten screw (1). 08044 1 © 39395 0 6 z Clean sealing surface on bleed pipe and cylinder head. z If available, install the bleed pipe (1) and reducer (2). 3 z Mount reducer with bleed pipe and new gasket, tighten screws (3). 1 03060 3 z Fix pipe clip (1).
Exhaust system / Charging W 06-07-03 2011 W 06-07-03 Remove and install air intake pipe Tools References - Commercial tools 8189 - Torx tool kit - W 06-01-05 6 Remove air intake pipe z Remove exhaust manifold Î Job card W 06-01-05. z Unscrew screws (arrows), remove air intake pipe and gaskets. © 39059 0 Install air intake pipe z Clean sealing surfaces on air intake pipe and cylinder head. 1 Note Note installation position of the gaskets (1).
Exhaust system / Charging W 06-07-03 2011 z Mount air intake pipe with new gaskets and tighten screws. z Tighten screws from the center outwards. 06030 z Install exhaust manifold Î Job card W 06-01-05.
Crankcase W 07-02-06 2011 W 07-02-06 Remove and install control linkage and guide bushes Tools References - Commercial tools - 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 - Special tools 110 140 - Assembly tool 150 140 - Extraction tool 150 150 - Assembly pin Auxiliary material - DEUTZ DW 72 6 Remove control linkage z Remove front cover Î Job card W 03-08-01.
Crankcase W 07-02-06 2011 z Knock out cylindrical pin (1). 1 © 39072 0 6 z Remove control linkage (1) with spring. 1 © 39073 0 Remove guide bush (opposite side to flywheel) z Insert assembly pin (1) in guide bush (2).
Crankcase W 07-02-06 2011 z Knock out guide bush. © 39075 0 6 Install guide bush (opposite side to flywheel) z Unscrew locking screw (1). 1 © 39076 0 z Push spacer bush (1) onto assembly pin (2). z Insert assembly pin in the centering (3). 2 Note The guide pin (arrow) must engage in the groove (4).
Crankcase W 07-02-06 2011 z Push guide bush (1) onto assembly pin. Note The chamfer (arrow) must face the crankcase in assembly. 1 © 39078 0 6 z Mount centering on crankcase. Note - The crankcase contact surface must be clean. - The fixing bolt (1) must engage the bore (2). 2 1 © 39079 0 z Tighten screw (1). z Knock in the guide sleeve until the assembly pin touches the spacer bush (arrow). 1 z Remove centering with assembly pin.
Crankcase W 07-02-06 2011 z Tighten new locking screw. Note The threaded bore for the locking screw must be free from oil, corrosion and dirt and be dry. 03007 © 39084 0 6 Remove oil rise pipe z Unscrew locking screw (1). z Remove oil thermostat Î Job card W 08-11-12. 1 © 39087 0 z Remove cap (1).
Crankcase W 07-02-06 2011 z Drill oil rise pipe (1) with a Ø 5.5 mm drill on one side. Note - Coat the drill with grease so that no drill chips fall into the crankcase. - Remove all drill chips. 1 © 39089 0 6 z Insert extraction tool (1) in the oil rise pipe until the bolt (2) snaps into the bore (arrow). 1 2 © 39093 0 z Mount spacer bush (1) and disc, tighten nut.
Crankcase W 07-02-06 2011 z Pull the oil rise pipe out of the lower press fit (arrow). Note Do not pull out the oil rise pipe completely. © 39097 0 6 z Press in bolt (arrow) and remove oil rise pipe. © 39098 0 Remove guide bush (flywheel side) z Insert assembly pin (1) in guide bush (2).
Crankcase W 07-02-06 2011 z Knock out guide bush. © 39204 0 6 Install guide bush (flywheel side) z Insert assembly pin (1) in centering (2). Note The guide pin (arrow) must engage in the groove (3). 2 1 3 © 39205 0 z Push guide bush (1) onto assembly pin. Note The chamfer (arrow) must face the crankcase in assembly.
Crankcase W 07-02-06 2011 z Insert assembly pin with guide bush. Note The crankcase contact surface must be clean. © 39227 0 6 z Mount centering on crankcase and tighten screw (1). z Knock in the guide sleeve until the assembly pin touches the centering (arrow). 1 z Remove centering with assembly pin. © 39228 0 Install oil rise pipe z Insert new oil rise pipe (1). Note The chamfer (arrow) must face the crankcase in assembly.
Crankcase W 07-02-06 2011 z Knock in the oil rise pipe until the assembly pin (1) touches the crankcase (arrow). 1 © 39232 0 6 z Coat new cap with DEUTZ DW 72 locking agent. © 33816 1 z Knock in cap flush with crankcase. z Install oil thermostat Î Job card W 08-11-12.
Crankcase W 07-02-06 2011 z Tighten new locking screw. Note The threaded bore for the locking screw must be free from oil, corrosion and dirt and be dry. 03007 © 39235 0 6 Install control linkage z 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. 1 2 © 39236 0 z Press together spring and insert cylindrical pin (1) in the bore (2).
Crankcase W 07-02-06 2011 z Drive in the cylindrical pin flush with the crankcase. z Install connection housing Î Job card W 03-09-04. z Install front cover Î Job card W 03-08-01. z Install injection pumps. Î Job card W 07-04-01 (Motorpal) Î Job card W 07-04-01 (Bosch) In BFL, BFM engines z Install charging pressure dependent full load stop Î Job card W 07-08-02. © 39238 0 6 In FM, BFM engines z Install generator Î Job card W 13-02-03. In FL, BFL engines z Install cooling blower Î Job card W 09-11-01.
Fuel system W 07-02-07 2011 W 07-02-07 Remove and install lifting magnet for start volume release Tools - Commercial tools 8027 - Pliers insert 6 Remove lifting magnet for start volume release z Pull cable plug (1) out of lifting magnet (2). 2 1 © 39662 0 z Unscrew lifting magnet (1) with pliers insert and remove sealing ring. Note Note clamping direction of the pliers insert. 1 z Check components for visible signs of damage.
Fuel system W 07-02-07 2011 Install lifting magnet for start volume release z Mount lifting magnet (1) with new CU sealing ring and tighten with pliers insert. 1 05065 © 39664 0 6 z Pull cable plug (1) out of lifting magnet (2).
Fuel system W 07-03-01 2011 W 07-03-01 Renew injection lines Tools Note - Commercial tools 8018 - Claw wrench 8189 - Torx tool kit - 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.
Fuel system W 07-03-01 2011 z Unscrew union nuts (1) from injection valve and injection pump with claw wrench. z Remove injection line. Note - Put down the components in the order of installation, note order of cylinders. - Seal openings on the injection valve and the injection pump. 1 1 © 39482 0 6 Install injection lines z Mount injection line on injection pump and injection valves and tighten union nuts (1). Note 1 Mount the injection lines without tension.
Fuel system W 07-03-01 2011 z Tighten screw (1). 1 © 39481 1 6 z Pre-tighten screw (1) on cylinder head. 09098 z Tighten screws (arrows). 09089 z Tighten screw (1) on cylinder head. 1 09098 z Install oil cooler Î Job card W 08-08-02.
Fuel system W 07-03-01 2011 Notes 6 © 11/2004 4/4 0312 1594 - 0138
Fuel system W 07-04-01 2011 W 07-04-01 Remove and install injection pumps (Bosch) Tools References - Commercial tools Depth-measuring appliance - W 07-03-01 - W 07-06-04 - W 07-10-06 - Special tools 100.710 - Setting bolt 100 880 - Marking pin 103 030 - Test template 6 Note Distinguishing features for the Bosch injection pump: - Short pump housing. © 39300 0 Remove injection pump 1 z Remove injection lines Î Job card W 07-03-01. 1 z Remove fuel supply line Î Job card W 07-10-06.
Fuel system W 07-04-01 2011 z 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. © 34044 1 6 Install the injection pump z Unscrew cap (arrow) and remove sealing ring. © 34173 1 z Move control linkage to mid position. Note Ignition off / stop magnet free. z Turn in setting bolt (1) to stop.
Fuel system W 07-04-01 2011 z Turn crankshaft until the cam for the respective injection pump is standing on the cam basic circuit (1). 1 © 39116 0 6 z Oil lightly and insert the roller tappet. Note - Note the assignment of the roller tappet. - The guide pin (1) on the roller tappet must engage in the groove (2). 2 1 © 39117 0 Determination of the compensation gasket Note Schematic representation for determining the depth "A".
Fuel system W 07-04-01 2011 Determine depth dimension z Measure depth dimension "A" from the crankcase rest to the spring head rest of the roller tappet. Note The crankcase rest must be clean. z Read and note measured value. © 34178 1 6 z 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.
Fuel system W 07-04-01 2011 z Select compensation gasket according to table. 07 21 9 12 21 15 24 18 27 © 34180 1 6 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 z Mount the appropriate compensation gasket. Note Note installation position, the recess (arrow) must face the flywheel.
Fuel system W 07-04-01 2011 z Pull out locking pin (1). Note Remove the gasket (2) together with the locking pin. 1 2 © 34183 1 6 z Insert the marking pin (1) in the bore of the injection pump and snap into the deflection lever (arrow). z Clamp the bracket of the marking pin. 1 © 34184 1 z Insert the injection pump centrally to the long holes. z Press in injection pump to stop and tighten nuts. z Tighten nuts.
Fuel system W 07-04-01 2011 z Loosen clamping bracket and pull out marking pin (1). 1 © 34186 1 6 z Press in locking pin (1) with gasket to stop. 1 © 34187 1 z Unscrew setting bolt (arrow).
Fuel system W 07-04-01 2011 z Tighten cap with new CU sealing ring. 03004 z Check beginning of pumping if necessary Î Job card W 07-06-04. z Install fuel supply line Î Job card W 07-10-06. z Install injection lines Î Job card W 07-03-01.
Fuel system W 07-04-01 2011 W 07-04-01 Remove and install injection pumps (Motorpal) Tools References - Commercial tools - W 07-03-01 - W 07-06-03 - W 07-06-04 - W 07-10-06 - Special tools 100 710 - Setting bolt 103 030 - Test template 101 100 - Marking pin 6 Note Distinguishing features for the Motorpal injection pump: - Long injection pump housing. - Overflow line on the injection pump. © 39484 0 Remove injection pump z Remove injection lines Î Job card W 07-03-01.
Fuel system W 07-04-01 2011 z Unscrew nuts (1), remove injection pump (2) and compensation gaskets. Note - Loosen nuts evenly to avoid jamming the injection pump. - Put down the components in the order of installation, note order of cylinders. 2 1 © 39111 0 6 z 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.
Fuel system W 07-04-01 2011 z Move control linkage to mid position. Note Ignition off / stop magnet free. z Turn in setting bolt (1) to stop. 1 © 39115 0 6 z Turn crankshaft until the cam for the respective injection pump is standing on the cam basic circuit (1). 1 © 39116 0 z Oil lightly and insert the roller tappet. Note - Note the assignment of the roller tappet. - The guide pin (1) on the roller tappet must engage in the groove (2).
Fuel system W 07-04-01 2011 z Determine the thickness of the shim gasket Î Job card W 07-06-03. z Select compensation gasket according to table. 07 21 9 12 21 15 24 18 27 © 34180 1 6 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 z Mount the appropriate compensation gasket. Note Note installation position, the recess (arrow) must face the flywheel.
Fuel system W 07-04-01 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 z Pull out locking pin (1). 1 Note Remove the gasket (2) together with the locking pin. 2 z Unscrew cap (3) and remove sealing ring. 3 © 39120 0 z Insert marking pin (1) in the bore (2) of the injection pump. Note Do not press in the marking pin completely.
Fuel system W 07-04-01 2011 z Position the center punch point (1) on the regulating sleeve (2) (arrow) so that it is underneath the tip of the marking pin. Note The center punch point is visible through the bore for the locking screw. 1 2 © 39122 0 6 z Position the tip of the marking pin (1) in the center punch point. 2 z Clamp the clamping bracket (2) of the marking pin. 1 © 39123 0 z Insert the injection pump centrally to the long holes. z Press in injection pump to stop and tighten nuts.
Fuel system W 07-04-01 2011 z Loosen clamping bracket and pull out marking pin (1). 1 © 39125 0 6 z Press in locking pin (1) with gasket to stop. z Tighten cap (2) with new CU sealing ring. 1 07071 2 © 39126 0 z Unscrew setting bolt. z Tighten locking screw (1) with new CU sealing ring. 03004 z Check beginning of pumping if necessary Î Job card W 07-06-04. z Install fuel lines Î Job card W 07-10-06. 1 z Install injection lines Î Job card W 07-03-01.
Fuel system W 07-04-01 2011 Notes 6 © 11/2004 8/8 0312 1596 - 0138
Fuel system W 07-06-03 2011 W 07-06-03 Determine the thickness of the shim gasket Tools References - Commercial tools 8170 - Depth measuring appliance - 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. 6 z Remove injection pump and compensation gasket. z Removal and installation of roller tappet, visual inspection.
Fuel system W 07-06-03 2011 z Place the depth measuring screw on the contact surface of the crankcase and keep it pressed against the stop. Turn the depth measuring screw until the probe is touching the roller tappet. © 39184 3 6 z 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).
Fuel system W 07-06-03 2011 z 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 6 z Read and note value of the pre-stroke correction from the company rating plate.
Fuel system W 07-06-03 2011 Notes 6 © 11/2004 4/4 0312 1638 - 0138
Fuel system W 07-06-04 2011 W 07-06-04 Check start of pumping Tools References - Commercial tools - W 07-03-01 - W 07-10-06 (Bosch) - W 07-10-06 (Motorpal) - W 11-00-03 - Special tools 100 120 - Connecting piece 101 300 - Pointer for degree scales 101 500 - Hand pump 101 510 - Tank 100 910 - Scale dial 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.
Fuel system W 07-06-04 2011 z 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 6 z Screw setting bolt (1) into the crankcase to the stop. 1 © 39186 0 Lock the crankshaft z Unscrew cap (1) and remove sealing ring.
Fuel system W 07-06-04 2011 z Insert setting bolt (1) in the bore (2) to lock the crankshaft. 2 1 © 39516 0 6 z Screw setting bolt (1) into the crankcase to the stop. Note The cylinder at the front cover is now in the ignition UT. 1 © 39188 0 z Loosen screw (1) and mount pointer with stop device (2). z Tighten screw.
Fuel system W 07-06-04 2011 z Mount scale dial on V-belt pulley. z Set pointer in line with "0°". © 39190 0 6 z Install overflow pipe (1) on pressure valve holder of the injection pump. z Install hose (2) on overflow pipe and supply tank. z Install high pressure hand pump (3) to injection pump (4) and supply tank. 1 3 Note Make sure that there is enough fuel in the supply tank. 2 4 © 39191 0 z Screw locking screw (1) into injection pump. Note 1 Do not tighten locking screw.
Fuel system W 07-06-04 2011 z Unscrew setting bolt for camshaft and crankshaft locking. z Turn crankshaft approx. 90° against the engine’s direction of rotation (arrow). © 39193 0 6 z Bleed the suction chamber of the injection pump. Actuate the high pressure hand pump until fuel emerges at the locking screw (1). 1 z Tighten the locking screw. 07071 © 39192 0 z Actuate the high pressure hand pump constantly. Note The fuel must flow evenly out of the overflow pipe.
Fuel system W 07-06-04 2011 z Read beginning of pumping from the dial. 07 31 © 39195 0 6 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 180° 3 cylinder engine 120° 4 cylinder engine 180° z Remove dial and pointer, tighten screw. z Remove high pressure hand pump and overflow pipe.
Fuel system W 07-06-04 2011 z Tighten locking screw (1) with new CU sealing ring. 03003 1 © 39185 0 6 z Tighten locking screw (1) with new CU sealing ring. 03003 z Install fuel lines Î Job card W 07-10-06 (Bosch) Î Job card W 07-10-06 (Motorpal) z Install injection lines Î Job card W 07-03-01. 1 z Install lifting magnet (shutdown magnet) Î Job card W 11-00-03.
Fuel system W 07-06-04 2011 Notes 6 © 11/2004 8/8 0312 1597 - 0138
Fuel system W 07-07-01 2011 W 07-07-01 Remove and install injection valves (in engines with leak fuel line) Tools References - Commercial tools 8011 - Clamping pliers - W 07-03-01 - Special tools 110 030 - Extractor 150 800 - Extraction tool Note - Cleanliness is extremely important when working on the injection equipment. - Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove injection valve z Remove injection lines Î Job card W 07-03-01.
Fuel system W 07-07-01 2011 z Pull out injection valve (1) and sealing ring (arrow). 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. 1 © 39486 0 6 Install injection valve z Mount new sealing ring (arrow) on injection valve. © 34191 1 z Insert injection valve. Note The leak fuel connection (arrow) must face the Manifold side.
Fuel system W 07-07-01 2011 z Mount the clamping claw and tighten the screw. Note Note installation position of the clamping claw. © 34193 1 6 z Tighten screw. 07001 © 34194 1 z Mount overflow pipe (1), attach hoses and tighten screws. 07062 1 z Attach return hose (2) and fix hose clip with clamping pliers. z Insert return hose in holder (arrows). Note The rubber hoses must always be renewed.
Fuel system W 07-07-01 2011 z Attach return hose (1) and fix hose clip with clamping pliers. Note Check return pipe, renew if necessary. z Install injection lines Î Job card W 07-03-01. 1 © 34203 1 6 Install injection valve (leak fuel-less) z Mount new sealing ring (1) on injection valve. 1 © 39487 0 z Insert injection valve (1). Note The flattened side (arrow) must face the Operating side.
Fuel system W 07-07-01 2011 z Mount the clamping claw and tighten the screw. Note Note installation position of the clamping claw. © 39488 0 6 z Press the clamping claw to touch the gate (arrow) on the injection valve (arrow) and tighten screw (1). 07001 z Install injection lines Î Job card W 07-03-01.
Fuel system W 07-07-01 2011 Notes 6 © 11/2004 6/6 0312 1598 - 0138
Fuel system W 07-07-02 2011 W 07-07-02 Check and repair injection valve Tools References - Commercial tools 8021 - Socket size 15 - W 07-07-05 - W 07-07-01 - Special tools 110 110 - Holder 6 Dismantle injection valve z Remove injection valves Î Job card W 07-07-01. z Insert injection valve in holder. z Unscrew nozzle clamping nut with long socket.
Fuel system W 07-07-02 2011 Check injection nozzle z The nozzle needle (1) must slide back to its seat slowly and jolt-free by its own weight when the nozzle body (2) is held vertically. 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.
Fuel system W 07-07-02 2011 z Insert compression spring. © 33907 1 6 z Insert compression bolt. Note The center joint must face the compression spring. © 33908 1 z Insert adapter with the centering pins in the bores in the nozzle holder. Note The countersink must face the compression bolt.
Fuel system W 07-07-02 2011 z Mount the injection nozzle with the centering bores on the centering pins of the adapter. Note The nozzle needle may not fall out of the nozzle body. © 33910 1 6 z Screw on the nozzle clamping nut. © 33911 1 z Tighten the nozzle clamping nut. 07002 z Remove the injection valve from the holder. z Check and set injection valves Î Job card W 07-07-05 z Install injection valves Î Job card W 07-07-01.
Fuel system W 07-07-05 2011 W 07-07-05 Check and set injection valves (leak fuel-less) Tools Caution! ! - Commercial tools 8008 - Nozzle tester 8021 - Socket size 15 - Special tools 110 110 - Holder 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.
Fuel system W 07-07-05 2011 Testing the opening pressure z Press down the lever of the nozzle tester slowly, with connected pressure gauge. The pressure at which the pointer stands still or suddenly drops is the opening pressure. 07 52 © 36293 1 6 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.
Fuel system W 07-07-05 2011 Order of single part assembly 123456- 6 Shim disc Compression spring Compression bolt Adapter Injection nozzle Nozzle clamping nut 1 2 3 4 5 © 36269 1 6 z Select shim disc, for correcting the opening pressure according to the spare parts list. Note A thicker disc gives a higher opening pressure. z Assemble injection valve and tighten nozzle clamping nut. 07002 z Check the injection valve on the nozzle tester again.
Fuel system W 07-07-05 2011 Note Injection nozzle is tight if it does not drip within 10 seconds. © 36294 1 6 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 z Switch off the tester’s pressure gauge. Note The easy action of the nozzle needle in the nozzle body is checked by the acoustic buzz test.
Fuel system W 07-07-05 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 6 Caution! ! The pressure in the spring space must be relieved in any case before installing the injection valves. z Loosen the nozzle clamping nut with the long socket approx.
Fuel system W 07-07-05 2011 Notes 6 © 11/2004 6/6 0312 1600 - 0138
Fuel system W 07-08-01 2011 W 07-08-01 Remove and install solenoid valve (LDA) Tools - Commercial tools 8027 - Pliers insert 6 Remove solenoid valve In BFL engines z Unscrew screws (1) and remove air duct cover (2). 2 1 1 © 39080 0 z Pull off cable plug from solenoid valve (1) if available.
Fuel system W 07-08-01 2011 z Unscrew solenoid valve (1) with pliers insert and remove sealing ring. Note Note clamping direction of the pliers insert. z Check components for visible signs of damage. 1 © 39666 0 6 Install solenoid valve z Mount solenoid valve (1) with new CU sealing ring and tighten with pliers insert. 06094 1 © 39667 0 z Plug cable plug to solenoid valve (1) if available.
Fuel system W 07-08-01 2011 In BFL engines z Mount air duct cover (1). Note The air duct cover must be under the stand plate and the profile rubber (arrows). 1 © 39490 0 6 z Fix air duct cover (2). Tighten screws (1).
Fuel system W 07-08-01 2011 Notes 6 © 11/2004 4/4 0312 1601 - 0138
Fuel system W 07-08-02 2011 W 07-08-02 Remove and install charge pressure full load stop (LDA) Tools Note - Commercial tools 8011 - Clamping pliers 8027 - Pliers insert - 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.
Fuel system W 07-08-02 2011 z Loosen the hose clips (1) with clamping pliers. 1 © 39382 0 6 z Pull off the fuel pipes (1). 1 © 39383 0 z Unscrew fuel filter (1) with special wrench. z Unscrew screws (2) and remove fuel filter console (3) with LDA.
Fuel system W 07-08-02 2011 z Unscrew screws (1), remove cover (2) with diaphragm. 2 1 © 39385 0 6 z Remove spring (1). 1 © 39386 0 z Unscrew solenoid valve (1) with pliers insert and remove sealing ring. 1 Note - Note clamping direction of the pliers insert. z Check components for visible signs of damage.
Fuel system W 07-08-02 2011 Install charging pressure dependent full load stop z Mount solenoid valve (1) with new CU sealing ring and tighten with pliers insert. 1 06094 © 39388 0 6 z Mount spring (1), diaphragms (2) and cover (3). Note Note the installation position of the cover, the underpressure connection must face upwards. 2 3 z Tighten screws. 07096 1 © 39389 0 z Clean the sealing surface on the fuel filter console and crankcase. z Renew the gasket (arrow).
Fuel system W 07-08-02 2011 z Mount fuel filter console (1) with LDA and tighten screws (2). 1 07095 z Oil sealing ring on fuel filter lightly. 2 z Tighten fuel filter hand tight. 07099 © 39391 0 6 z 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. 1 © 39393 0 z Plug cable plug to solenoid valve (1) if available. z Plug on the underpressure line (2).
Fuel system W 07-08-02 2011 In FL, BFL engines z Mount air duct cover (1). Note The air duct cover must be under the stand plate and the profile rubber (arrows). 1 © 39490 0 6 z Fix air duct cover (2). Tighten screws (1).
Fuel system W 07-10-06 2011 W 07-10-06 Remove and install fuel lines (with Bosch injection pumps) Tools References - Commercial tools 8011 - Clamping pliers - W 08-08-02 Note Caution! ! Collect drained operating materials in suitable vessels and dispose of according to regulations. Observe the safety regulations and and national specifications for handling fuels! 6 Remove fuel lines In FL, BFL engines z Unscrew screws (1) and remove air duct cover (2).
Fuel system W 07-10-06 2011 z Loosen hose clip and pull off return pipe (1). z Unscrew hollow screws (2), remove fuel supply line (3) and sealing rings. z Check components for visible signs of damage. 1 3 2 2 © 39483 0 6 Install fuel supply line z Push fuel supply line (1) through the profile rubber (arrow) and position. z Tighten hollow screws (2) with new CU sealing rings. 1 07015 2 2 © 39367 0 z Attach return hose (1) and fix hose clip with clamping pliers.
Fuel system W 07-10-06 2011 z Attach fuel hose (1) and fix hose clip with clamping pliers. Note Check fuel pipe and renew if necessary. 1 © 34205 1 6 In FL, BFL engines z Mount air duct cover (1). Note The air supply cover must be under the stand plate and the profile rubber (arrows). 1 © 39490 0 z Fix air duct cover (2). Tighten screws (1).
Fuel system W 07-10-06 2011 Remove overflow pipe 1 In FL, BFL engines 3 z Remove oil cooler Î Job card W 08-08-02. z Loosen pipe clips (1) and pull off return pipes (2). z Unscrew screws and remove overflow pipe (3). z Check components for visible signs of damage. 2 © 34031 1 6 Install overflow pipe z Mount overflow pipe (1), attach hoses and tighten screws. 1 07062 z Attach return hose (2) and fix hose clip with clamping pliers. z Insert return hose in holder (arrows).
Fuel system W 07-10-06 2011 W 07-10-06 Remove and install fuel lines (with Motorpal injection pumps) Tools Caution! ! - Commercial tools 8011 - Clamping pliers 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. 6 Remove fuel lines In FL, BFL engines z Unscrew screws (1) and remove air duct cover (2).
Fuel system W 07-10-06 2011 z Unscrew hollow screws (1), remove fuel supply line (2) and sealing rings. z Check components for visible signs of damage. 2 1 1 © 39491 0 6 Install fuel supply line z Push fuel supply line (1) through the profile rubber (arrow) and position. 1 z Tighten hollow screws (2) with new CU sealing rings. 2 07015 2 © 39438 0 z Attach fuel hose (1) and fix hose clip with clamping pliers. Note Check fuel pipe and renew if necessary.
Fuel system W 07-10-06 2011 Remove overflow pipe In FL, BFL engines z Unscrew screws (1) and remove standing plate (2). 1 2 1 © 39081 0 6 z Unscrew hollow screws (1), remove overflow pipe (2) and sealing rings. Note 1 Remove overflow pipe to flywheel side. 1 z Check components for visible signs of damage. 2 © 39492 0 Install overflow pipe z Mount overflow pipe (2), tighten hollow screws (1) with new CU sealing rings.
Fuel system W 07-10-06 2011 In FL, BFL engines 2 z Mount the standing plate and tighten the screws. Note - Note different screw length (1 and 2). - The oil cooler must be on the latch (arrow). 1 z Tighten screws (1 and 2). 09070 2 © 39493 0 6 z Mount air duct cover (1). Note The air supply cover must be under the stand plate and the profile rubber (arrows). 1 © 39490 0 z Fix air duct cover (2). Tighten screws (1).
Fuel system W 07-10-08 2011 W 07-10-08 Remove and install fuel filter console Tools Caution! ! - Commercial tools 8011 - Clamping pliers Observe the safety regulations and national specifications for handling fuels! - Special tools 170 050 - Special wrench Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove fuel filter console Remove fuel filter z Unscrew fuel filter (1) with special wrench.
Fuel system W 07-10-08 2011 z Unscrew screws (1) and remove fuel filter console (2). 1 z Check components for visible signs of damage. 2 © 39068 0 6 Install fuel filter console z Mount fuel filter console (2) and tighten screws (1). 1 07082 2 © 39068 0 z Attach fuel pipes (2) and fix pipe clips (1) with clamping pliers. 1 Note - Check fuel pipes and renew if necessary. - Observe assignment of the fuel pipes.
Fuel system W 07-10-08 2011 Install fuel filter z Oil sealing ring on fuel filter lightly. z Tighten new fuel filter hand tight.
Fuel system W 07-10-08 2011 Notes 6 © 11/2004 4/4 0312 1605 - 0138
Fuel system W 07-11-01 2011 W 07-11-01 Remove and install fuel pump Tools Caution! ! - Commercial tools 8011 - Clamping pliers 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. 6 Remove fuel pump z Pull out oil dipstick (1). z Loosen pipe clip (2) with clamping pliers and pull off fuel pipe (3). 1 3 2 © 39030 0 z Unscrew screws (1).
Fuel system W 07-11-01 2011 Install fuel pump z Clean the sealing surface on the fuel pump and crankcase. z Pull new round sealing ring (arrow) onto fuel pump. © 39207 0 6 z Mount fuel pump. z Press in fuel pump to stop and tighten screws (1). 1 z Tighten screws. 07024 1 © 39225 0 z Attach fuel hose (3) and fix hose clip (2) with clamping pliers. Note 1 Check fuel pipe and renew if necessary. z Insert oil dipstick (1).
Lube oil system W 08-04-05 2011 W 08-04-05 Remove and install lube oil pump Tools References - Commercial tools - 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. 6 Remove lube oil pump z Remove toothed belt and clamping roller Î Job card W 04-04-12 (old version) Î Job card W 04-04-12 (new version) z Pull out oil dipstick (1). 1 z Unscrew screws (2).
Lube oil system W 08-04-05 2011 Install lube oil pump z Clean the sealing surface on the lube oil pump and crankcase. z Renew the gasket (1). 1 © 39496 0 6 z Check all clamping sleeves are in place (arrows). © 39497 0 z Insert lube oil pump (1) and attach to clamping sleeves (2).
Lube oil system W 08-04-05 2011 z Tighten screws (1). 08010 z Insert oil dipstick (2). 2 z Install toothed belt and clamping roller Î Job card W 04-04-12 (old version) Î Job card W 04-04-12 (new version).
Lube oil system W 08-04-05 2011 Notes 6 © 11/2004 4/4 0312 1607 - 0138
Lube oil system W 08-04-06 2011 W 08-04-06 Remove and install oil intake pipe Tools References - Commercial tools - W 08-04-07 Auxiliary material - DEUTZ DW 74 6 Remove oil intake pipe z Remove lube oil tray Î Job card W 08-04-07 z Unscrew screws (1) and remove oil intake pipe (2). 2 1 © 39499 0 Install oil intake pipe z Clean the sealing surface on the oil intake pipe and crankcase. z Apply sealant DEUTZ DW 74 to the oil intake pipe (arrow).
Lube oil system W 08-04-06 2011 z Mount oil intake pipe (1) and tighten screws (2). Note Do not move the sealant when mounting the oil intake pipe. 08015 z Install lube oil tray Î Job card W 08-04-07.
Lube oil system W 08-04-07 2011 W 08-04-07 Remove and install lube oil tray Tools - Commercial tools 8189 - Torx tool kit Auxiliary material - DEUTZ DW 74 Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove lube oil tray z Unscrew locking screw (1) and drain engine oil. z Tighten locking screw with new sealing ring. 03031 1 © 39551 0 In engines with connection housing z Unscrew screws (arrows) and remove cover plate (1).
Lube oil system W 08-04-07 2011 z Unscrew all screws (arrow) and remove lube oil tray. © 39628 0 6 Install lube oil tray z Clean the sealing surface on the lube oil tray and crankcase. z Apply sealant DEUTZ DW 74 (arrows). Note Make sure no sealant gets into the oil channel (1). 1 © 34253 1 z Mount lube oil tray. Note Do not move the sealant when mounting the lube oil tray.
Lube oil system W 08-04-07 2011 z 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 6 Tightening order 4-cylinder z Tighten all bolts in the right order. 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) z Tighten all screws in the right order.
Lube oil system W 08-04-07 2011 Tightening order 3-cylinder z Tighten all screws in the right order. 03030 © 34258 1 6 Tightening order 2-cylinder z Tighten all screws in the right order. 03030 © 34259 1 In engines with connection housing z Fit cover plate (1) and tighten screws (arrows). 03085 1 z Fill in prescribed engine oil.
Lube oil system W 08-08-02 2011 W 08-08-02 Remove and install oil cooler Tools - Commercial tools 8189 - Torx tool kit Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil cooler z Unscrew screws (1) and remove air duct cover. 2 1 1 © 39080 0 z Unscrew screws (1) and remove standing plate (2).
Lube oil system W 08-08-02 2011 z Unscrew screws (1) and pull oil cooler up. 1 © 39554 0 6 z Pull connections (1) out of crankcase. 1 1 © 39556 0 Install oil cooler z Check connections for visible signs of damage.
Lube oil system W 08-08-02 2011 z Press connections (1) into the crankcase to the stop. Note X The side with the long joint ”X” must face upwards. 1 © 39281 0 6 z Press the oil cooler onto the connections to the stop. Note Insert connections (1) in the bores (arrows). 1 1 © 39622 0 z Turn on screws (1). Note Do not tighten screws.
Lube oil system W 08-08-02 2011 z Mount the standing plate and turn on the screws. 2 Note - Note different screw length (1 and 2). - The oil cooler must be on the latch (arrow). 1 09070 2 © 39493 0 6 z Tighten screws (1 and 3). 09070 3 2 z Tighten screws (2). 08051 1 © 39623 0 z Mount air duct cover (1). Note The air duct cover must be under the stand plate and the profile rubber (arrows).
Lube oil system W 08-08-02 2011 z Fix air duct cover (2). Tighten screws (1).
Lube oil system W 08-08-02 2011 Notes 6 © 11/2004 6/6 0312 1610 - 0138
Lube oil system W 08-10-06 2011 W 08-10-06 Remove and install oil filter cartridge Tools - Commercial tools - Special tools 170 050 - Special wrench Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil filter cartridge z Unscrew oil filter cartridge (1) with special device (2). 1 2 © 39040 0 Install oil filter cartridge z Oil the sealing ring of the new oil filter cartridge lightly and screw on hand tight.
Lube oil system W 08-10-06 2011 Notes 6 © 11/2004 2/2 0312 1611 - 0138
Lube oil system W 08-11-02 2011 W 08-11-02 Remove and install oil pressure regulating valve, check Tools - Commercial tools Caliper gauge Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 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.
Lube oil system W 08-11-02 2011 z Check components for visible signs of wear. © 39061 0 6 z Measure length of the compression spring with caliper gauge. 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) z Insert valve piston (1) and compression spring (2). 1 Note - Use compression spring with green mark (3 bar opening pressure). - Oil the valve piston lightly. - Note installation order.
Lube oil system W 08-11-02 2011 z Tighten cap (1) with new CU sealing ring. 08098 1 © 39060 0 6 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 1 © 39065 0 Remove oil pressure regulating valves (with heater connection) z Unscrew caps (1) and remove sealing rings.
Lube oil system W 08-11-02 2011 z Unscrew transfer nipple (1) for heater supply and remove sealing ring. z Unscrew transfer nipple (2) for heater return and remove sealing ring. 1 Note When removing the transfer nipple (2) the following parts may jump out under the pressure of the compression spring. 2 © 34080 1 6 z Unscrew caps (1) and remove sealing ring. Note When removing the cap the following parts may jump out under the pressure of the compression spring.
Lube oil system W 08-11-02 2011 z Check components for visible signs of wear. © 39061 0 6 z Measure length of the compression springs with caliper gauge. 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) 1 z Insert valve piston and compression springs (1, 2 and 3). Note - Note the assignment of the compression springs Item Opening pressure Color marking 1 1.
Lube oil system W 08-11-02 2011 Note - Note installation position of the valve pistons (arrows). - Oil the valve piston lightly. 08 41 08 42 08 43 © 39518 0 6 z Tighten caps (1) with new CU sealing rings. 08098 1 © 34079 1 z Install new sealing rings (1) at the transfer nipple. 1 Note The countersink on the sealing rings (arrow) must face the crankcase.
Lube oil system W 08-11-02 2011 z Tighten the transfer nipple (1) for the heater supply. z Tighten transfer nipple (2), with valve seat, for heater return. 1 08061 2 © 34080 1 6 z Tighten caps (1) with new CU sealing rings.
Lube oil system W 08-11-02 2011 Notes 6 © 11/2004 8/8 0312 1612 - 0138
Lube oil system W 08-11-07 2011 W 08-11-07 Remove and install oil filter console Tools References - Commercial tools - W 08-10-06 Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil filter console z Remove oil filter cartridge Î Job card W 08-10-06. z Unscrew hollow screw (1) and remove sealing rings. 1 © 39042 0 z Unscrew screws (1) and remove oil filter console (2).
Lube oil system W 08-11-07 2011 z Remove gasket (1). z Check components for visible signs of damage. 1 © 39044 0 6 Install oil filter console z Clean the sealing surface of the oil filter console and crankcase. 1 z Mount oil filter console (2) with new gasket and tighten screws (1). 1 08003 2 © 39043 0 z Tighten hollow screw (1) with new CU sealing rings. 08048 z Install oil filter cartridge Î Job card W 08-10-06.
Lube oil system W 08-11-08 2011 W 08-11-08 Remove and install oil pressure switch Tools - Commercial tools Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil pressure switch z Pull cable plug (1) out of oil pressure switch (2). 1 2 © 39051 0 z Unscrew oil pressure switch (1) with sealing ring. z Check component for visible signs of damage.
Lube oil system W 08-11-08 2011 Install oil pressure switch z Tighten oil pressure switch (2) with sealing ring. 08091 1 z Plug cable plug (1) to oil pressure switch.
Lube oil system W 08-11-09 2011 W 08-11-09 Remove and install oil pressure sensor Tools - Commercial tools - Special tools 170 110 - Special wrench Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil pressure sensor z Pull off cable plug from oil pressure sensor (1) if available. 1 © 39524 0 z Unscrew oil pressure sensor (1) with special wrench and remove sealing ring. z Check components for visible signs of damage.
Lube oil system W 08-11-09 2011 Install oil pressure sensor z Mount oil pressure sensor (1) with new CU sealing ring and tighten with special wrench. 08093 1 © 39525 0 6 z Plug cable plug to oil pressure sensor (1) if available.
Lube oil system W 08-11-12 2011 W 08-11-12 Remove and install oil thermostat (oil cooler) Tools - Commercial tools Caliper gauge Auxiliary material - Assembly sleeve Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil thermostat (oil cooler) In FL, BFL engines z Unscrew screws (1) and remove air duct cover (2). 2 1 1 © 39080 0 z Unscrew screws (1) and remove standing plate (1).
Lube oil system W 08-11-12 2011 z Unscrew cap (1), remove oil thermostat with compression spring. Note When removing, the following parts may jump out under the pressure of the compression spring. 1 © 39083 0 6 z Check components for visible signs of wear. © 39437 0 z Measure length of the compression spring with caliper gauge. Note If the wear limit is reached, the compression spring has to be changed.
Lube oil system W 08-11-12 2011 Install oil thermostat (oil cooler) z Insert oil thermostat (1) with compression spring. Note - Oil the oil thermostat lightly. - Note installation order. 1 © 39086 0 6 z Pull the new round sealing ring onto the cap. Note Use the assembly sleeve. 1 z Tighten locking screw (1). 08072 © 39083 0 In FL, BFL engines 2 z 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).
Lube oil system W 08-11-12 2011 z Mount air duct cover (1). Note The air duct cover must be under the stand plate and the profile rubber (arrows). 1 © 39490 0 6 z Fix air duct cover (2). Tighten screws (1).
Lube oil system W 08-15-01 2011 W 08-15-01 Remove and install oil pressure line (turbocharger) Tools - Commercial tools Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil pressure l-ine z Unscrew hollow screws (1), remove oil pressure line (2) and sealing rings. 2 z Check components for visible signs of damage. 1 1 © 39397 0 Install oil pressure line z Mount oil pressure line (2), tighten hollow screws (1) with new CU sealing rings.
Lube oil system W 08-15-01 2011 Notes 6 © 11/2004 2/2 0312 1618 - 0138
Lube oil system W 08-15-02 2011 W 08-15-02 Remove and install oil return line (turbocharger) Tools - Commercial tools Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil return line z Unscrew screw (1) and remove holder. 1 © 39395 0 z Pull oil return line (1) out of the crankcase and pull off from oil return pipe flange support (2).
Lube oil system W 08-15-02 2011 z Unscrew screws (1), remove oil return pipe flange support (2) and gasket. z Check components for visible signs of damage. 1 2 © 39398 0 6 Install oil return line z Clean the sealing surface of the turbocharger and oil return pipe flange support. z Mount oil return pipe flange support (1) with new gasket and tighten screws (2). 1 08044 © 39627 0 z Pull new round sealing ring (arrow) onto oil return pipe flange support.
Lube oil system W 08-15-02 2011 z Pull new round sealing ring (arrow) onto oil return line. © 39378 0 6 z 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 z Mount holder and tighten screw (1).
Lube oil system W 08-15-02 2011 Notes 6 © 11/2004 4/4 0312 1619 - 0138
Lube oil system W 08-16-01 2011 W 08-16-01 Remove and install oil line for injection adjuster supply Tools - Commercial tools Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil line z Pull cable plug (1) out oil pressure switch. 1 z Unscrew screws (2), remove fuel filter console (3) and hang aside. 2 3 © 39200 0 z Unscrew hollow screws (1), remove oil line (2) and sealing rings. 2 z Check components for visible signs of damage.
Lube oil system W 08-16-01 2011 Install oil line z Mount oil line (2), tighten hollow screws (1) with new CU sealing rings. 2 08048 1 1 © 39202 0 6 z Fit fuel filter console (3) and tighten screws (2). 07082 1 2 z Plug cable plug (1) to oil pressure switch.
Lube oil system W 08-16-02 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. 6 Remove oil temperature sensor (injection adjustment) z Unscrew cap (1), remove oil temperature sensor with compression spring and remove slide regulator.
Lube oil system W 08-16-02 2011 z Measure length of the compression spring with caliper gauge. Note If the wear limit is reached, the compression spring has to be changed. 08 74 © 39062 0 6 Install oil temperature sensor (injection adjustment) z Insert temperature sensor, compression spring and slide regulator. 1 Note - Oil temperature sensor lightly. - Note installation order. z Tighten locking screw (1) with new CU sealing ring.
Lube oil system W 08-11-11 2011 W 08-11-11 Remove and install oil temperature sensor Tools References - Commercial tools - W 08-08-02 Note Collect drained operating materials in suitable vessels and dispose of according to regulations. 6 Remove oil temperature sensor In FL, BFL engines z Remove oil cooler Î Job card W 08-08-02. z Unscrew screw (1). 1 © 39481 0 z Unscrew screws (1) and remove air duct (2).
Lube oil system W 08-11-11 2011 z Pull cable plugs (1and 2) from the oil temperature sensor. Note Note the assignment of the cable plugs. 1 2 © 39266 0 6 z Unscrew oil temperature sensor (1) and remove sealing ring. 1 © 39265 0 z Check components for visible signs of damage.
Lube oil system W 08-11-11 2011 Install oil temperature sensor z Tighten oil temperature sensor (1) with new sealing ring. 08095 1 © 39265 0 6 z Plug cable plugs (1 and 2) into oil temperature sensor (2). Note Note the assignment of the cable plugs. 1 2 © 39266 0 In FL, BFL engines z Mount air duct (2) and tighten screws (1).
Lube oil system W 08-11-11 2011 z Tighten screw (1). 1 © 39481 1 6 z Pre-tighten screw (1) on cylinder head and tighten screws (arrows). 09089 z Tighten screw (1) on cylinder head. 09089 1 z Install oil cooler Î Job card W 08-08-02.
Cooling system W 09-11-01 2011 W 09-11-01 Remove and install cooling blower Tools References - Commercial tools 8189 - Torx tool kit - W 12-02-01 (FL, BFL engines) 6 Remove cooling blower z Remove V-belt Î Job card W 12-02-01. z Unscrew screws (1) and remove air duct cover (2). 2 1 1 © 39080 0 z Remove cable from generator. Unscrew nut (1) and remove cable ”G1.W” (2). z Unscrew nut (3) and remove cable ”G1.D+” (4).
Cooling system W 09-11-01 2011 z Unclip cable plug (1). 1 © 39561 0 6 z Unscrew screws (1) and remove cable holders (arrows). 1 1 © 39611 0 z Unscrew screws (1) and remove cooler blower with generator. z Check components for visible signs of damage.
Cooling system W 09-11-01 2011 Install cooling blower z Mount cooler blower with generator and tighten screws. 09066 © 39564 0 6 z Position cable holders (arrows) and tighten screws. Note Note different screw length: Screw M6 x 12 mm (1) Screw M8 x 20 mm (2) 1 z Tighten screw (1 and 2). 2 13092 © 39271 0 z Clip in cable plug (1).
Cooling system W 09-11-01 2011 z Plug cable to generator. Attach cable "G1.D+" (4) and tighten nut (3). 1 2 13082 z Attach cable "G1.W" (2) and tighten nut (1). 13083 3 4 © 39560 0 6 z Mount air duct cover (1). Note The air duct cover must be under the stand plate and the profile rubber (arrows). 1 © 39490 0 z Fix air duct cover (2). Tighten screws (1). 09087 2 z Install V-belt. Î Job card W 12-02-01.
Cooling system W 09-11-02 2011 W 09-11-02 Dismantle and complete cooling blower, check Tools References - Commercial tools 8189 - Torx tool kit - W 09-11-01 6 Dismantle cooling blower z Remove cooling blower Î Job card W 09-11-01. z Unscrew screws (arrows) and remove blower jacket inlet (1). 1 © 39565 0 z Unscrew nut (1). Note Hold shaft.
Cooling system W 09-11-02 2011 z Remove disc (1), V-belt pulley (2) and running wheel (3). 1 2 3 © 39567 0 6 z Remove spacer disc (1). 1 © 39568 0 z Remove guide disc (1).
Cooling system W 09-11-02 2011 z Unscrew nut (1) and press out rubber muff (1). 1 2 © 39570 0 6 z Unscrew nuts (1) and press out generator. z Visually inspect components and renew if necessary. 1 1 © 39571 0 Complete cooler blower z Insert generator and press in to stop. Note Note installation position of the generator.
Cooling system W 09-11-02 2011 z Mount washers and tighten nuts (1) alternately. Note Check the installation position again. 1 09065 1 © 39571 0 6 z Mount guide disc (1). 1 Note The stepped side (arrow) must face the generator. © 39573 0 z Mount spacer disc (1).
Cooling system W 09-11-02 2011 z Mount running wheel (3), V-belt pulley (2) and disc. 1 Note Note installation position. 2 3 © 39567 0 6 z Tighten nut. 13021 © 39575 0 Check gap dimension z Press out the protective grille (1) carefully from the blower jacket inlet at the fastening points (arrows). Note Do not damage the protective grille.
Cooling system W 09-11-02 2011 z Mount blower jacket inlet (1) and tighten screws (2). Note Note the installation position, the gates (arrows) must be in line. 1 09067 2 2 © 39577 0 6 z Measure the gap dimension with a feeler gauge between the running wheel and the blower jacket inlet. 09 91 © 39578 0 z Compensate gap dimension with the appropriate spacer disc (1). 1 Note Spacer discs of 5 to 7 mm are available.
Cooling system W 09-11-02 2011 z Press the protective grille (1) carefully into the blower jacket inlet. Note Observe the fastening points. 1 © 39579 0 6 z Insert rubber muff (1) and tighten nut (2). 13081 1 z Install cooler blower Î Job card W 09-11-01.
Cooling system W 09-11-02 2011 Notes 6 © 11/2004 8/8 0312 1622 - 0138
Cooling system W 09-13-01 2011 W 09-13-01 Dismantle and complete fan drive Tools - Commercial tools 6 Dismantle fan drive z If available, unscrew screws (arrows) and remove fan. © 34014 1 z Unscrew screws (arrows) and remove V-belt pulley.
Cooling system W 09-13-01 2011 z Remove locking ring (arrow). © 34006 0 6 z Press out ball bearing with shaft (arrow). © 34007 1 z Pull the inner (1) and outer (2) ball bearing from the shaft. 2 z Check components for visible signs of damage. 1 Note The ball bearings must always be renewed.
Cooling system W 09-13-01 2011 Complete fan drive z Press the inner ball bearing (1) over the outer ring up to the stop. 1 © 34009 1 6 z Press in the shaft (1) to the stop in the inner ball bearing. 1 Note - Note installation position of the shaft. - Support the inner ring of the ball bearing when pressing in. © 34010 1 z Press in the outer ball bearing (1) over the outer and inner ring up to the stop.
Cooling system W 09-13-01 2011 z Insert locking ring (arrow). Note Pay attention to correct fit of the locking ring in the groove. © 34006 0 6 z Mount V-belt pulley and tighten screws (arrows). 12046 © 34005 1 z Mount fan if available and tighten screws (arrows). Note Note different strength classes of the screws.
Monitoring system W 11-00-03 2011 W 11-00-03 Remove and install lifting magnet (shutoff magnet) Tools References - Commercial tools - W 12-02-06 - W 13-02-03 (FM, BFM engines) 6 Remove lifting magnet (shutdown magnet) In FM, BFM engines z Remove generator Î Job card W 13-02-03. In FL, BFL engines z Remove V-belt clamping roller Î Job card W 12-02-06. z Unscrew screw (arrow) and pull off cable plug (1). 1 © 39038 0 z Unscrew screws (1) and remove lifting magnet (2).
Monitoring system W 11-00-03 2011 z Pull new round sealing ring (1) onto lfiting magnet. 1 © 39036 0 6 Install lifting magnet z Insert lifting magnet (2) and tighten screws (1). 1 05041 2 1 © 39039 0 z Plug cable plug (1) and tighten screw (arrow). In FL, BFL engines z Install V-belt clamping roller Î Job card W 12-02-06. In FM, BFM engines z Install generator Î Job card W 13-02-03.
Other components W 12-02-01 2011 W 12-02-01 Check V-belt, renew (in FL and BFL engines) Tools Caution! ! - Commercial tools 8115 - V-belt pulley tension measuring appliance 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. 6 Test V-belt z Inspect the V-belt visually for wear all round. © 39626 0 Renew V-belt z Loosen screws (1).
Other components W 12-02-01 2011 z Fit V-belt. z Tighten V-belt. Press the V-belt clamping roller (1) in the direction of the arrow with a suitable tool and tighten the screw (2). 2 12041 1 © 39581 0 6 Check the V-belt tension with the V-belt tension measuring appliance. z Lower indicator arm (1) into V-belt tension measuring appliance (2). 1 2 © 39582 0 z Mount V-belt tension measuring appliance on the V-belt. Note The V-belt must be between the guides (arrow).
Other components W 12-02-01 2011 z Press the V-belt measuring appliance against the V-belt with the button (1) until you hear it click. z 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 1 12 21 z If the setpoint is not reached, the clamping procedure must be repeated. © 39584 0 6 z Tighten screw (1).
Other components W 12-02-01 2011 Notes 6 © 11/2004 4/4 0312 1625 - 0138
Other components W 12-02-01 2011 W 12-02-01 Check, renew V-belt (in FM, BFM engines) Tools Caution! ! - Commercial tools 8115 - V-belt pulley tension measuring appliance 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. 6 Test V-belt z Inspect the V-belt visually for wear all round.
Other components W 12-02-01 2011 z Swing generator aside (arrow). z Remove V-belt. © 39372 0 6 z Fit V-belt. z 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. z Lower indicator arm (1) into V-belt tension measuring appliance (2).
Other components W 12-02-01 2011 z Mount V-belt tension measuring appliance on the V-belt. Note The V-belt must be between the guides (arrow). © 39522 0 6 z Press the V-belt measuring appliance against the Vbelt with the button (1) until you hear it click. z 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 1 z If the setpoint is not reached, the clamping procedure must be repeated.
Other components W 12-02-01 2011 Generator fastening with built-up fan drive (unit design) z Tighten screw (1). 1 13016 2 z Tighten screw (2). 13015 z Tighten screw (3). 3 13012 © 34289 1 6 Generator fastening with built-up fan drive (building machine design) 1 z Tighten screw (1). 13012 3 z Tighten screw (2). 13016 z Tighten screw (3).
Other components W 12-02-06 2011 W 12-02-06 Remove and install V-belt clamping roller Tools References - Commercial tools - 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. 6 Remove V-belt clamping roller z Unscrew screws (1) and remove V-belt clamping roller (2). 1 z Check component for visible signs of damage.
Other components W 12-02-06 2011 Notes 6 © 11/2004 2/2 0312 1627 - 0138
Other components W 12-06-01 2011 W 12-06-01 Remove and install flywheel Tools - Commercial tools - Special tools Guide pin (self made) 143 100 - Pressing device 6 Remove flywheel z Unscrew all screws (arrow). Note Block flywheel with suitable tool. z Remove flywheel. © 34065 1 Remove stuck flywheel z Turn in self-made guide pin (arrow). z Apply pressing tool (1) and tighten screws (2).
Other components W 12-06-01 2011 z Press down flywheel by turning in the center screw (1). z Remove pressing tool. z Unscrew self-made guide pin (arrow). z Visually inspect the flywheel and toothed starter ring for damage. 1 © 34066 1 6 Install flywheel z Mount flywheel using a self-made guide pin (arrow). © 34224 1 z Tighten all screw with angled wrench alternately. Note - Use new screws. - Block flywheel with suitable tool.
Other components W 12-06-03 2011 W 12-06-03 Renew toothed starter at flywheel ring Tools Caution! ! - Commercial tools Risk of injury! From hot parts. References - W 12-06-01 6 Remove toothed starter ring z Remove flywheel Î Job card W 12-06-01. z Drill toothed starter ring. Note Do not damage the flywheel. © 33837 1 z Remove toothed starter ring with suitable tool.
Other components W 12-06-03 2011 z Clean the flywheel and inspect visually at the joint (arrow). © 33839 1 6 Install toothed starter ring z Heat up toothed starter ring to max. 220 °C. Mount toothed starter ring and contact at collar. z Install flywheel. Î Job card W 12-06-01.
Other components W 12-08-02 2011 W 12-08-02 Remove and install hydraulic pump Tools - Commercial tools Auxiliary material - Graphite grease G 500, 20g tube 6 Remove hydraulic pump z Unscrew hexagon bolts (1), remove hydraulic pump (2) and coupling sleeve. 1 2 © 39090 0 z Visually inspect hydraulic pump (1), coupling sleeve (2) and jackets (3) for damage, change if necessary.
Other components W 12-08-02 2011 Install hydraulic pump z Pull jackets (1 and 2) onto coupling sleeve (3). 3 Note The punch-out of the jackets must be aligned to the teeth of the coupling sleeve. z Grease the inside teeth of the coupling sleeve with graphite grease G 500. 1 2 © 39092 0 6 z Grease the toothed shaft with graphite grease G 500. z Plug the coupling sleeve (2) to the toothed shaft. 2 Note - Note installation position. - The teeth of the coupling sleeve must engage the toothed shaft.
Other components W 12-08-02 2011 z Grease the toothed shaft of the hydraulic pump drive with graphite grease G 500. z Insert hydraulic pump (2) with coupling sleeve and tighten hexagon bolts (1). Note 1 The teeth of the coupling sleeve must engage the hydraulic pump drive.
Other components W 12-08-02 2011 Notes 6 © 11/2004 4/4 0312 1630 - 0138
Other components W 12-08-03 2011 W 12-08-03 Remove and install toothed belt and clamping roller of the hydraulic pump Tools Caution! ! - Commercial tools The toothed belt and the clamping roller must be renewed after every disassembly regardless of their time in operation.
Other components W 12-08-03 2011 z Unscrew screws (1) and remove V-belt pulley (2). Note Hold at the center screw. 2 1 1 © 39354 0 6 z Remove centrifugal disc (1). 1 © 39355 0 z Unscrew screws (1) and remove protective cover (2).
Other components W 12-08-03 2011 z Remove adapter (1). 1 © 39601 0 6 z Unscrew screw (1) and remove clamping roller (2). z Remove toothed belt (3). 1 z Check components for visible signs of damage. 2 3 © 39590 0 Install toothed belt and clamping roller z Insert new clamping roller with the guide fork (1) of the base plate in the guide pin (2) of the hydraulic pump console.
Other components W 12-08-03 2011 z Screw in screw (1) and position setting eccenter (arrow) at 12.00 h position. z Pre-tighten screw. 12052 1 © 39592 0 6 z Mount new toothed belt. Note Note running direction of the toothed belt. The labeling (arrow) on the toothed belt must be legible from the front. © 39593 0 z 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).
Other components W 12-08-03 2011 z Remove locking pin (1). 1 © 34235 1 6 z 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 2 Turn the setting eccenter at the hexagon socket. z Tighten screw (2). 12052 1 © 39595 0 z Turn the crankshaft 2 turns in the engine’s direction of rotation (arrow). z Check the toothed belt tension.
Other components W 12-08-03 2011 Correct the toothed belt tension z Loosen screw (2) and pre-tighten again. 12052 2 z 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). z Tighten screw (2). 12052 1 © 39595 0 6 z Mount adapter (1). Note The flattened side (arrow) must face the toothed belt. 1 © 39597 0 z Mount protective cover (2) and tighten screws (1).
Other components W 12-08-03 2011 z Mount centrifugal disc (1). Note The hollow gorge must face the adapter. 1 © 39598 0 6 z Fit V-belt pulley (1) and tighten screws (2) alternately. Note 1 Hold at the center screw. 2 12031 2 © 39599 0 In FM, BFM engines z If available, mount V-belt pulley and flange hub (1). z Tighten (2) screws alternately.
Other components W 12-08-03 2011 z Mount fan and disc, tighten screws (1). 09042 z Install V-belt.
Electrical system W 13-01-02 2011 W 13-01-02 Remove and install cable harness Tools - Commercial tools Note The repair procedure refers to FL, BFL engines. In FM, BFM engines the repair procedure must be performed accordingly. 6 z Unscrew screws (1) and remove air duct cover (2). 2 1 1 © 39080 0 Remove cable harness z Remove cable from generator. Unscrew nut (1) and remove cable ”G1.W” (2). 1 2 z Unscrew nut (3) and remove cable ”G1.D+” (4).
Electrical system W 13-01-02 2011 z Unclip cable plug (1). 1 © 39561 0 6 z Pull out cable plug (1), with black housing, with cable "B3.WK" from the oil temperature sensor. 1 2 z Pull out the cable plug (2), without housing, with cable ”B3.G” from the oil temperature sensor. © 39444 0 z 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.
Electrical system W 13-01-02 2011 z Pull off cable plug from solenoid valve (1) if available. 1 © 39665 0 6 z Unscrew screw (1) and remove cable plug (2) from engine shutdown. 1 2 © 394410 z Pull off profile rubber (1) from the clamping pins and remove the cable harness.
Electrical system W 13-01-02 2011 z Visually inspect the cable harness. Note The connections to the cable harness depend on the engine requirements. © 39440 0 6 Install cable harness z Insert the cable harness in the profile rubber (1) and plug the profile rubber to the clamping pins. 1 © 39442 0 z Plug the cable plug (2) to the engine shutdown and tighten the screw (1).
Electrical system W 13-01-02 2011 z Plug cable plug to solenoid valve (1) if available. 1 © 39665 0 6 z 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. z Plug the cable plug (2) with cable to the release magnet. 1 2 © 39443 0 z Plug cable plug (1), with black housing, with cable "B3.WK" to the oil temperature sensor.
Electrical system W 13-01-02 2011 z Clip in cable plug (1). 1 © 39561 0 6 z Connect cable to generator. z Attach cable "G1.W" (4) and tighten nut (3) . 1 2 13083 z Attach cable "G1.D+" (2) and tighten nut (1). 3 13082 4 © 39560 0 z Mount air duct cover (1). Note The air duct cover must be under the stand plate and the profile rubber (arrows).
Electrical system W 13-01-02 2011 z Fix air duct cover (2). Tighten screws (1).
Electrical system W 13-01-02 2011 Notes 6 © 11/2004 8/8 0312 1632 - 0138
Electrical system W 13-02-03 2011 W 13-02-03 Remove and install generator (in FL and BFL engines) Tools References - Commercial tools 8189 - Torx tool kit - W 12-02-01 6 Remove generator z Remove V-belt Î Job card W 12-02-01. z Unscrew screws (1) and remove air duct cover (2). 2 1 1 © 39080 0 z Remove cable from generator. Unscrew nut (1) and remove cable ”G1.W” (2). z Unscrew nut (3) and remove cable ”G1.D+” (4).
Electrical system W 13-02-03 2011 z Unclip cable plug (1). 1 © 39561 0 6 z Unscrew screws (1) and remove cable holders (arrows). 1 1 © 39611 0 z Unscrew screws (1) and remove cooler blower with generator.
Electrical system W 13-02-03 2011 Remove generator from cooling blower z Unscrew screws (arrows) and remove blower jacket inlet (1). 1 © 39565 0 6 z Unscrew nut (1). Note Hold shaft. 1 © 39566 0 z Remove disc (1), V-belt pulley (2) and running wheel (3).
Electrical system W 13-02-03 2011 z Remove spacer disc (1). 1 © 39568 0 6 z Remove guide disc (1). 1 © 39569 0 z Unscrew nut (2) and press out rubber muff (1).
Electrical system W 13-02-03 2011 z Unscrew nuts (1) and press out generator. z Visually inspect components and renew if necessary. 1 1 © 39571 0 6 Install generator in cooling blower z Insert generator and press in to stop. Note Note installation position of the generator. © 39572 0 z Mount washers and tighten nuts (1) alternately. Note Check the installation position again.
Electrical system W 13-02-03 2011 z Mount guide disc (1). 1 Note The stepped side (arrow) must face the generator. © 39573 0 6 z Mount spacer disc (1). 1 © 39574 0 z Mount running wheel (3), V-belt pulley (2) and disc. 1 Note Note installation position.
Electrical system W 13-02-03 2011 z Tighten nut. 13021 © 39575 0 6 Check gap dimension z Press out the protective grille (1) carefully from the blower jacket inlet at the fastening points (arrows). Note Do not damage the protective grille! 1 © 39576 0 z Mount blower jacket inlet (1) and tighten screws (2). Note Note the installation position, the gates (arrows) must be in line.
Electrical system W 13-02-03 2011 z Measure the gap dimension with a feeler gauge between the running wheel and the blower jacket inlet. 09 91 © 39578 0 6 z Compensate gap dimension with the appropriate spacer disc (1). 1 Note Spacer discs of 5 to 7 mm are available. © 39574 0 z Press the protective grille (1) carefully into the blower jacket inlet. Note Observe the fastening points.
Electrical system W 13-02-03 2011 z Insert rubber muff (1) and tighten nut (2). 13081 1 2 © 39580 0 6 Install generator z Mount cooler blower with generator and tighten screws. 09066 © 39564 0 z Position cable holders (arrows) and tighten screws. Note Note different screw length: Screw M6 x 12 mm (1) Screw M8 x 20 mm (2) 1 z Tighten screw (1). 2 13092 z Tighten screw (2).
Electrical system W 13-02-03 2011 z Clip in cable plug (1). 1 © 39561 0 6 z Plug cable to generator. Attach cable "G1.D+" (4) and tighten nut (3). 1 2 13082 z Attach cable "G1.W" (2) and tighten nut (1). 13083 3 4 © 39560 0 z Mount air duct cover (1). Note The air duct cover must be under the stand plate and the profile rubber (arrows).
Electrical system W 13-02-03 2011 z Fix air duct cover (2). Tighten screws (1). 09087 2 z Install V-belt. Î Job card W 12-02-01.
Electrical system W 13-02-03 2011 Notes 6 © 11/2004 12/12 0312 1633 - 0138
Electrical system W 13-02-03 2011 W 13-02-03 Remove and install generator and holder (in FM, BFM engines) Tools References - Commercial tools 8189 - Torx tool kit - W 12-02-01 Note One variant has been described. The procedure is the same accordingly for other variants. 6 Remove generator z Remove cable from generator if available. Item (1) D+ Item (2) B+ Item (3) W z Remove V-belt Î Job card W 12-02-01. © 39445 0 z Unscrew nut (arrow), remove screw (1) and washers.
Electrical system W 13-02-03 2011 z Unscrew screw (1) and remove generator. 1 © 39448 0 6 z Unscrew screws (1) and remove console (2). 2 1 © 39449 0 z Unscrew screw (1) and remove clamping bracket (2). z Check components for visible signs of damage.
Electrical system W 13-02-03 2011 Install generator z Mount clamping bracket (2) and tighten screw (1). Note Note installation position of the clamping bracket. 1 2 © 39446 0 6 z Mount console (2) and tighten screws (1). 13010 2 1 © 39449 0 z Insert generator and tighten screw (1).
Electrical system W 13-02-03 2011 z Insert screw (1) and washers, tighten nut (arrow). z Install V-belt. Î Job card W 12-02-01. 1 © 39447 0 6 z Plug cable into generator if available. Item (1) D+ Item (2) B+ Item (3) W © 39445 0 Console fastening with built-up fan drive (unit design) z Tighten screws (1 and 2). 1 13010 z Tighten screw (3).
Electrical system W 13-02-03 2011 Console fastening with built-up fan drive (building machine design) z Tighten screws (1). 1 13010 z Tighten screw (2).
Electrical system W 13-02-03 2011 Notes 6 © 11/2004 6/6 0312 1634 - 0138
Electrical system W 13-03-02 2011 W 13-03-02 Remove and install starter Tools - Commercial tools 6 Remove starter z If available, remove the heat shield (1). Unscrew screws (2). 2 1 © 39380 0 z Unscrew screw (1) and remove cable holder (2). z Unscrew nut (3) and remove charging current cable (4).
Electrical system W 13-03-02 2011 z Unscrew screws (1) and remove starter. 1 1 © 39541 0 6 z Insert starter and tighten screws (1). 1 13001 1 © 39542 0 z Connect charging current cable (4) and tighten nut (3). 1 13071 z Position cable holder (2) and tighten screw (1).
Electrical system W 13-03-02 2011 z If available, install the heat shield (1). Tighten screws (2).
Electrical system W 13-03-02 2011 Notes 6 © 11/2004 4/4 0312 1635 - 0138
Electrical system W 13-06-01 2011 W 13-06-01 Remove and install helical heater plug Tools - Commercial tools 6 Remove helical heater plugs z Unscrew helical heater plugs (1) and remove sealing rings. z Check components for visible signs of damage. 1 1 © 39033 0 Install helical heater plugs z Tighten helical heater plug (1) with new CU sealing ring.
Electrical system W 13-06-01 2011 Notes 6 © 11/2004 2/2 0312 1636 - 0138
2011 7 Commercial tools 7 Please send all tool orders directly to: WILBÄR Wilhelm Bäcker 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: a.zarrath@wilbaer.de (Ms. Zarrath) other countries: a. karsten@wilbaer.de (Ms.
7 Commercial tools 2011 Notes 7 © 11/2004 2/8 0312 1640 - 0138
7 Commercial tools 2011 8005 - Compression tester 2 for diesel engines 10-40 bar Set 8005 8008 - © 35410 2 7 Nozzle tester 2 with spray mist collector 8008 8011 - Clamping pliers © 35411 2 1 for leak fuel lines 8011 © 11/2004 3/8 © 39426 0 0312 1640 - 0138
7 Commercial tools 2011 8018 - Claw wrench 2 Size 17 for union nuts of the injection lines, reinforced 8018 7 8021 - Socket size 15 © 37506 1 2 long, hexagonal ½, for union nut injection valve 8021 8024 - Assembly pliers © 39427 0 2 for valve shaft sealing, for removing the valve shaft seal 8024 © 11/2004 4/8 © 37509 1 0312 1640 - 0138
7 Commercial tools 2011 8027 - Pliers insert 1 for solenoid valve 8027 8036 - © 39531 0 7 Socket 2 size 32, set with 8049 8036 8049 - Force multiplier © 39429 0 2 for center screw on the crankshaft, set with 8036 8049 © 11/2004 5/8 © 39430 0 0312 1640 - 0138
7 Commercial tools 2011 8112 - Insert 2 for screwdriver, 1/2" size 17 8112 7 8115 - V-belt pulley tension measuring appliance © 39431 0 1 150 to 600 N, test the V-belt pulley tension 8115 8170 - Depth measuring appliance 2 8170 © 11/2004 © 35416 2 6/8 © 39532 0 0312 1640 - 0138
7 Commercial tools 2011 8189 - Torx tool kit 1 8189 9017 - © 39432 0 7 Assembly lever 2 for valve spring 9017 9088 - Clamping pliers © 37511 1 1 for hose clips, 220 mm, spring clamps 9088 © 11/2004 7/8 © 39433 0 0312 1640 - 0138
7 Commercial tools 2011 9090 - Clamping pliers 1 for hose clips, 320 mm, clamping spring clamps 9090 7 9120 - Special bit, 70 mm long © 35420 2 2 IPR 30, 70 mm long, for secure screwing on regulator 9120 9122 - Special bit, 25 mm long © 39434 0 2 IPR 30, 25mm long, for secure screwing on regulator 9122 © 11/2004 8/8 © 39435 0 0312 1640 - 0138
2011 8 Special tools 8 Please send all tool orders directly to: WILBÄR Wilhelm Bäcker 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: a.zarrath@wilbaer.de (Ms. Zarrath) other countries: a. karsten@wilbaer.de (Ms.
8 Special tools 2011 Notes 8 © 11/2004 2/16 0312 1641 - 0138
8 Special tools 2011 100 120 - Connecting piece 2 for compression tester 100 120 100 400 - © 39400 0 8 Meter 4 in connection with 100 750 100 400 100 690 - Marking pin © 37605 1 2 for Bosch injection pump 100 690 © 11/2004 3/16 © 39368 0 0312 1641 - 0138
8 Special tools 2011 100 700 - Setting bolt 2 for toothed belt assembly Crankshaft and camshaft 100 700 8 100.
8 Special tools 2011 100 880 - Marking pin 2 for Bosch injection pumps Wire length 64mm Note No longer available. Replaced by marking pin 100 690.
8 Special tools 2011 101 500 - Hand pump 2 High pressure hand pump for testing and setting the static beginning of pumping 101 500 8 101 510 - Tank © 36443 1 2 Supply tank for high pressure hand pump 101 510 101 910 - Device © 36444 1 2 for reading the angle degrees 101 910 © 11/2004 6/16 © 36449 1 0312 1641 - 0138
8 Special tools 2011 103 030 - Test template 2 for compensation gasket of the injection pump 103 030 110 030 - © 39533 0 8 Extractor 2 for injection valve in connection with 150 800 © 35433 2 110 110 - Holder 2 for injection valve SW11 to accommodate the injection valve in the vice 110 110 © 11/2004 7/16 © 35431 2 0312 1641 - 0138
8 Special tools 2011 110 140 - Assembly tool 2 for control linkage bushes 110 140 8 120 900 - Clamping block © 39407 0 2 for cylinder head, swivelling 120 900 120 910 - Clamping plate © 35438 2 2 for clamping plate 120 900 if this is not screwed tight 120 910 © 11/2004 8/16 © 35439 2 0312 1641 - 0138
8 Special tools 2011 121 410 - Assembly tool 2 for valve shaft seals 121 410 130 300 - © 37614 1 8 Universal piston ring pliers 2 Disassemble and assemble piston rings 130 300 130 420 - Trapezoidal wear gauge 2 130 420 © 11/2004 © 35441 2 9/16 © 36461 1 0312 1641 - 0138
8 Special tools 2011 130 630 - Piston ring tensioning band 2 130 630 8 131 100 - Disassembly tool © 39408 0 3 for piston bolt lock 131 100 131 340 - Assembly tool for FL/M engines © 39409 0 2 for piston bolt bush of FL/M engines 131 340 © 11/2004 10/16 © 39410 0 0312 1641 - 0138
8 Special tools 2011 131 350 - Assembly tool for BF/M engines 2 for piston bolt bush of BF/M engines 131 350 142 050 - © 39411 0 8 Press-in device 2 for camshaft sealing ring 142 050 142 850 - Assembly tool © 39412 0 2 for camshaft sealing ring without running ring, opposite side to flywheel 142 850 © 11/2004 11/16 © 39414 0 0312 1641 - 0138
8 Special tools 2011 142 860 - Assembly tool 2 for camshaft sealing ring without running ring, flywheel side 142 860 8 143 100 - Pressing device © 39415 0 2 for flywheel 143 100 143 420 - Holder © 39416 0 2 for force multiplier 143 420 © 11/2004 12/16 © 39417 0 0312 1641 - 0138
8 Special tools 2011 143 430 - Intermediate disc 2 for holder 143 420 143 430 143 820 - © 39418 0 8 Assembly tool 2 for camshaft bearing 143 820 144 130 - Holder © 39419 0 2 for camshaft wheel 144 130 © 11/2004 13/16 © 39420 0 0312 1641 - 0138
8 Special tools 2011 150 140 - Extraction tool 2 for oil pipe in crankcase 150 140 8 150 150 - Assembly pin © 39421 0 2 for oil pipe in crankcase 150 150 150 800 - Extraction tool © 39422 0 1 e.g.
8 Special tools 2011 170 050 - Special wrench 1 for filter cartridge, for unscrewing the filter cartridge 170 050 170 110 - © 37629 1 8 Special wrench 2 for oil pressure sensor 170 110 6067 - Engine assembly stand 2 6067 © 11/2004 © 39423 0 15/16 © 39424 0 0312 1641 - 0138
8 Special tools 2011 6067/114 - Support arm 2 6067/114 8 6067/115 - Clamping holder 2 6067/115 © 11/2004 © 39369 0 16/16 © 39425 0 0312 1641 - 0138