Workshop Manual competence level 2 D Th is do i cu s al tr m lo ib en w u ed ti o ti sc w n ith in 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.
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 © 11/2004 4 © 39619 0 Cylinder head ID No.
4 Technical data 4.1 Test and adjustment data 2011 ID No. 01 61 01 62 Name Valve clearance (inlet) Valve clearance (outlet) Additional information • after a cooling time of at least 0.5 h (oil temperature < 80 °C) Unit 0.3 ±0.05 • Test and setting values in inspections from a running time of 50 operating hours of the engine or life of the cylinder head gasket (see maintenance schedule) • Setting values when changing the cylinder head gasket (0.4 ±0.05) • after a cooling time of at least 0.
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 98 Length of the cylinder head screw 02 00 Standard + 0.8 150.000 - 0.8 mm 4 Drive system ID No.
4 Technical data 4.1 Test and adjustment data 09 00 ID No. 09 91 4 2011 Cooling system Name Additional information Value Unit min. = 0.2 max. = 0.8 mm Additional information Value Unit Gap dimension between running wheel and blower jacket inlet 12 00 Other components ID No.
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 03000 Crankcase ID no. Name 03060 Crankcase bleeding on: • Front cover • Cylinder head cover • Cylinder head Pretightening value Re-tightening value Remark 8.
4 Technical data 4.2 Tightening specifications 2011 05000 Speed governing ID no. Name Pretightening value 05041 Lifting magnet (shutoff magnet) on front cover 8.5 Nm 05065 Lifting magnet (start volume release) on front cover 10 Nm Re-tightening value Remark Re-tightening value Remark 06000 Exhaust system / Charging ID no.
4 Technical data 4.2 Tightening specifications ID no. Name 07061 Overcurrent line to injection pump 4 2011 Pretightening value Re-tightening value • Renew CU sealing rings • Hollow screw 29 Nm 07062 Overcurrent line to cylinder head bolt 8.
4 Technical data 4.2 Tightening specifications 2011 ID no. Name 08072 Locking screw oil cooler thermostat on crankcase 08091 Oil pressure switch (locking screw) on crankcase 08093 Oil pressure sensor on crankcase 08095 Oil temperature sensor on crankcase Pretightening value 50 Nm 13 ± 1.5 Nm Re-tightening value Remark Hexagon socket Oil pressure switch M10 x 1mm 20 +2 Nm 25 ± 2.
4 Technical data 4.2 Tightening specifications 2011 09000 Cooling system ID no.
4 Technical data 4.2 Tightening specifications 2011 13000 Electrical components ID no. Name 13001 Starter on crankcase 13006 Starter console on crankcase Pretightening value 75 ± 7 Nm 8.
4 Technical data 4.2 Tightening specifications ID no. Name 2011 Pretightening value Re-tightening value Remark 13081 Charging current cable on generator B+ 5.5 -7 Nm 13082 Cable G1.D+ on generator 4.5 ± 0.8 Nm 13083 Cable G1.W on generator 4 Nm 13092 Cable harness holder on crankcase 14 Nm Torx screw M8 x 16mm Cable harness holder on: Starter crankcase 8.
2011 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.
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.
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
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
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.
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 07-07-01 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 07-08-01 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 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. z Tighten hollow screws (2) with new CU sealing rings. 1 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 07-10-06 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 z Remove oil cooler Î Job card W 08-08-02. 3 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 07-10-08 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 08-08-02 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 08-11-07 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 08-11-11 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.
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.
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 z Install V-belt. Î Job card W 12-02-01.
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, 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 z Tighten screw (2). 3 13016 z Tighten screw (3).
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 12-02-06 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 12-08-02 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
Electrical components 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 components 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 components 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 components 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 components 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 components 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 components W 13-01-02 2011 z Fix air duct cover (2). Tighten screws (1).
Electrical components W 13-01-02 2011 Notes 6 © 11/2004 8/8 0312 1632 - 0138
Electrical components 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 components 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 components 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 components 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 components 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 components 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 components 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 components 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 components 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 components 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 components W 13-02-03 2011 z Fix air duct cover (2). Tighten screws (1). 09087 z Install V-belt. Î Job card W 12-02-01.
Electrical components W 13-02-03 2011 Notes 6 © 11/2004 12/12 0312 1633 - 0138
Electrical components 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 components 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 components 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 components 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 components 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 components W 13-02-03 2011 Notes 6 © 11/2004 6/6 0312 1634 - 0138
Electrical components 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 components 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 components W 13-03-02 2011 z If available, install the heat shield (1). Tighten screws (2).
Electrical components W 13-03-02 2011 Notes 6 © 11/2004 4/4 0312 1635 - 0138
Electrical components 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 components 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 Tel. : +49 (0) 2191 - 9339-0 Fax : +49 (0) 2191 - 9339-200 E-mail: info@wilbaer.de Web: http://www.deutz-tools.
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 Tel. : +49 (0) 2191 - 9339-0 Fax: +49 (0) 2191 - 9339-200 E-mail: info@wilbaer.de Web: http://www.deutz-tools.
8 Special tools 2011 Notes 8 © 11/2004 2/6 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 100 750 100 400 100 750 - Measuring device © 37605 1 2 with shim discs for piston overhang and front cover in connection with 100 400 100 750 © 11/2004 3/6 © 39402 0 0312 1641 - 0138
8 Special tools 2011 110 030 - Extractor 2 for injection valve in connection with 150 800 © 35433 2 8 110 110 - Holder 2 for injection valve SW11 to accommodate the injection valve in the vice 110 110 143 100 - Pressing device © 35431 2 2 for flywheel 143 100 © 11/2004 4/6 © 39416 0 0312 1641 - 0138
8 Special tools 2011 150 800 - Extraction tool 1 e.g.
8 Special tools 2011 6067 - Engine assembly block 2 6067 8 6067/114 - Support arm 2 6067/114 6067/115 - Clamping holder © 39369 0 2 6067/115 © 11/2004 © 39424 0 6/6 © 39425 0 0312 1641 - 0138
