Workshop Manual
Table Of Contents
- Workshop Manual
- Foreword
- General
- User notes
- Technical data (Test and adjustment data)
- Technical data (Tightening specification)
- Job card overview (Sorted alphabetically)
- Job card overview (Sorted numerically)
- Job card overview (Job card references)
- W 00-02-06 Check compression
- W 00-05-01 Mount engine on assembly stand and disassemble
- W 01-01-01 Check and set valve clearance
- W 01-02-02 Remove and install toggle lever and toggle lever block
- W 01-02-06 Disassemble and complete, check toggle lever and toggle lever block
- W 01-04-04 Remove and install cylinder head
- W 03-01-11 Remove and install crankcase bleeding
- W 06-01-05 Remove and install exhaust manifold
- W 06-06-04 Remove and install turbocharger
- W 06-07-03 Remove and install air intake pipe
- W 07-02-07 Remove and install lifting magnet for start volume release
- W 07-03-01 Renew injection lines
- W 07-07-01 Remove and install injection valves (in engines with leak fuel line)
- W 07-08-01 Remove and install solenoid valve (LDA)
- W 07-08-02 Remove and install charge pressure full load stop (LDA)
- W 07-10-06 Remove and install fuel lines (with Motorpal injection pumps)
- W 07-10-06 Remove and install fuel lines (with Bosch injection pumps)
- W 07-10-08 Remove and install fuel filter console
- W 07-11-01 Remove and install fuel pump
- W 08-08-02 Remove and install oil cooler
- W 08-10-06 Remove and install oil filter cartridge
- W 08-11-07 Remove and install oil filter console
- W 08-11-08 Remove and install oil pressure switch
- W 08-11-09 Remove and install oil pressure sensor
- W 08-11-11 Remove and install oil temperature sensor
- W 08-11-12 Remove and install oil thermostat (oil cooler)
- W 08-15-01 Remove and install oil pressure line (turbocharger)
- W 08-15-02 Remove and install oil return line (turbocharger)
- W 08-16-01 Remove and install oil line for injection adjuster supply
- W 09-11-01 Remove and install cooling blower
- W 11-00-03 Remove and install lifting magnet (shutoff magnet)
- W 12-02-01 Check, renew V-belt (in FM, BFM engines)
- W 12-02-01 Check V-belt, renew (in FL and BFL engines)
- W 12-02-06 Remove and install V-belt clamping roller
- W 12-06-01 Remove and install flywheel
- W 12-08-02 Remove and install hydraulic pump
- W 13-01-02 Remove and install cable harness
- W 13-02-03 Remove and install generator (in FL and BFL engines)
- W 13-02-03 Remove and install generator (in FM and BFM engines)
- W 13-03-02 Remove and install starter
- W 13-06-01 Remove and install helical heater plug
- Commercial tools
- Special tools
0312 1650 - 0138
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© 11/2004
1
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. The user will bear the sole risk in this
case.
z Use for the intended purpose also includes observance of the operating, maintenance and repair
instructions specified by the manufacturer. The engine may only be used, maintained and repaired by
persons who are familiar with it and instructed in the dangers.
z Make sure that this documentation is available to everyone involved in the operation, maintenance and
repair and that they have understood the contents.
z Failure to observe this documentation can lead to malfunctions and engine damage as well as
injury to persons for which the manufacturer will accept no liability.
z Prerequisite for the proper maintenance and repair is the availability of all necessary equipment,
commercial tools and special tools as well as their perfect working order.
z Engine parts such as springs, clamps, elastic retaining rings etc. constitute an increased risk of injury when
not used properly.
z The pertinent rules for the prevention of accidents and other generally recognized safety and industrial
medicine rules must be observed.
z Maximum cost effectiveness, reliability and long life is only guaranteed when DEUTZ original parts are
used.
z Repair of the engine must comply with use for the intended purpose. Only parts released by the
manufacturer for the respective purpose may be used for conversion work. Unauthorized modification to the
engine exclude manufacturer liability for resulting damages. Failure to observe this will lead to voiding of the
warranty!
z The engines made by DEUTZ are developed for a wide range of applications. A wide range of variants
ensures that the respective special requirements are met.
z The engine is equipped according to the installation, i.e. not all the parts and components described in this
documentation are installed in your engine.
z We have done our best to clearly identify the differences so that you can easily find the operating,
maintenance and repair instructions relevant to your engine.
We are at your service for any questions you may have in this matter.
Your DEUTZ AG