Workshop Manual
Table Of Contents
- Workshop Manual
- 1 Foreword
- 2 General
- 3 User notes
- 5 Job card overview
- 5.1 Sorted alphabetically
- 5.2 Sorted numerically
- 6 Job cards
- Checking the compression pressure
- Mounting engine on assembly block and demounting
- Setting valve clearance
- Removing and installing the rocker arm and rocker arm bracket
- Renewing the crankshaft sealing ring (flywheel side)
- Renewing the crankshaft sealing ring (opposite side to flywheel)
- Removing and installing the crankcase bleeding
- Removing and installing rear cover
- Removing and installing the connection housing
- Renew camshaft sealing ring (opposite side to flywheel)
- Check control times
- Renew toothed belt and tensioning pulley
- Removing and installing the toothed belt wheel
- Removing and installing the impulse transmitter
- Removing and installing the exhaust damper
- Removing and installing the exhaust line
- Removing and install the charge air line
- Removing and installing the turbocharger
- Removing and installing the intake manifold
- Removing and installing the exhaust gas return valve
- Removing and installing the exhaust gas return pipe
- Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation)
- Removing and installing the sensor (Exhaust gas recirculation)
- Removing and installing the magnet clip (Exhaust gas recirculation)
- Removing and installing the lifting magnet (Start amount release)
- Renewing the injection lines
- Removing and installing the fuel injector pump
- Check start of injection
- Calculating the thickness of shim
- Removing and installing the fuel injectors
- Removing and installing the lifting magnet (charge air pressure-dependent full load stop)
- Installing and removing charge air pressure-dependent full load stop
- Removing and installing fuel pipes
- Removing and installing the fuel filter console
- Removing and installing the fuel filter console
- Removing and installing the fuel supply pump
- Removing and installing the lubricating oil pump
- Removing and installing the oil suction pipe
- Removing and installing the lubricating oil pan (metal sheet lubricating oil pan)
- Removing and installing the lubricating oil cooler
- Removing and installing the oil pressure regulating valve
- Removing and installing the oil filter console
- Removing and installing the oil pressure switch
- Removing and installing temperature transmitter
- Removing and installing the thermostat (Lubricating oil cooler)
- Removing and installing the control line
- Remove and install the cooling blower
- Dismantling and assembling the cooling blower
- Removing and installing air duct
- Removing and installing the air bearing
- Removing and installing the lifting magnet (Engine shutdown)
- Removing and installing the V-belt pulley
- Renew V-belts, check V-belt tension
- Removing and installing the flywheel
- Removing and installing the hydraulic pump
- Renew toothed belt and tensioning pulley (Hydraulic pump)
- Removing and installing the generator
- Removing and installing the starter
- Removing and installing the starter
- Removing and installing the heating plugs
- Removing and installing the glow plug
- 7 Standard tools
- 8 Special tools
1
© 05/2005 OBJ_DOKU-23450-001.fm
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DEUTZ engines Foreword
● Read and observe the information in this docu-
mentation. You will avoid accidents, retain the
manufacturer's warranty and possess a fully
functional and ready to operate engine.
● This engine is built exclusively for purpose ac-
cording to the scope of delivery - defined by the
equipment manufacturer (use for the intended
purpose). Any use above and beyond this is con-
sidered improper use. The manufacturer will not
be liable for damages resulting from this. The
user bears the sole risk.
● Use for the intended purpose also includes ob-
servance of the operating, maintenance and re-
pair instructions specified by the manufacturer.
The engine may only be used, maintained and
repaired by persons who are familiar with this
and are aware of the risks involved.
● Make sure that this documentation is available to
everyone involved in the operation, maintenance
and repair and that they have understood the
contents.
● Failure to observe this documentation may lead
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
● Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
● Engine parts such as springs, clamps, elastic re-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
● The pertinent rules for the prevention of acci-
dents and other generally recognised health and
safety regulations must be observed.
● Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
● Repair of the engine must correspond to its use
for the intended purpose. Only parts released by
the manufacturer for the respective purpose may
be used for conversion work. Unauthorised mod-
ifications to the engine exclude manufacturer lia-
bility for resulting damages. Failure to observe
this will void the warranty!
● The engines made by DEUTZ are developed for
a wide range of applications. A wide range of var-
iants ensures that the respective special require-
ments are met.
● The engine is equipped according to the installa-
tion case, i.e. not all the parts and components
described in this documentation are installed in
your engine necessarily.
● We have done our best to highlight the differenc-
es so that you can easily find the operating, main-
tenance and repair instructions relevant to your
engine.
We are at your service for any questions you may
have in this matter.
Your DEUTZ AG