Workshop Manual
Table Of Contents
- Frontpage
- Table of contents
- Checking the compression pressure
- Mounting engine on assembly block and demounting
- Setting valve clearance
- Removing and installing the rocker arm and rocker arm bracket
- Disassembling, assembling and checking the rocker arm and rocker arm bracket
- Removing and installing cylinder head
- Checking piston overhang
- Removing and installing the crankcase bleeding
- 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 lifting magnet (Start amount release)
- Renewing the injection lines
- 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 supply pump
- Removing and installing the lubricating oil cooler
- Removing and installing the oil filter console
- Removing and installing the oil pressure switch
- Removing and installing the thermostat (Lubricating oil cooler)
- Removing and installing the control line
- Removing and installing the coolant pump
- Checking the thermostat (in the removed state)
- Removing and installing the thermostat
- Removing and installing the thermostat housing
- Removing and installing temperature transmitter
- 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
- Removing and installing the generator
- Removing and installing the starter
- Removing and installing the heating plugs
- Removing and installing the glow plug
- 7 Standard tools
- 8 Special tools
3
© 06/2008 17764-001
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DEUTZ enginesUser notes
3.3 Operation manual and workshop
manual
To structure the information to suit the user, the
service documentation is divided into operation
manual and workshop manual.
The operation manual contains a general descrip-
tion and instructions for all other maintenance work.
It contains the following chapters:
1. Contents, General
2. Engine description
3. Operation
4. Operating media
5. Maintenance
6. Care and maintenance work
7. Faults, causes and remedies
8. Engine conservation
9. Technical data
10.Service
The workshop manual assumes knowledge of the
contents of the operation manual. This applies es-
pecially for the safety regulations. The workshop
manual describes repairs to the engine and compo-
nents for which more effort and appropriately quali-
fied technicians are required.
3.4 Job cards
The job cards are divided in the workshop manual
into "W" and "I" job cards.
The "W" job card documents standard repairs on the
engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
card.
The "I" job card additionally documents the appro-
priate work procedures for repairing the engine and/
or its components. The workshop must satisfy spe-
cial conditions to perform these work procedures.
Special tools and machine tools must be available,
for example.
3.4.1 Numbering of job cards
The job card numbers follow the pattern W 02-04-
01. The individual parts of this pattern are explained
below:
z W 02-04-01: Documentation type
– WWorkshop manual
– I ...... Repair instructions
z W 02-04-01: Maintenance group
– 00 ... General / interdisciplinary activities
– 01 ...Cylinder head
– 02Drive system
– 03 ... Crankcase
– 04 ... Engine control system
– 05 ...Speed governing
– 06 ... Exhaust system / Charging
– 07 ... Fuel system
– 08 ... Lube oil system
– 09 ...Cooling system
– 10 ...Compressed air system
– 11 ... Monitoring system
– 12 ...Other components
– 13 ... Electrical system
z W 02-04-01: Component grouping
z W 02-04-01: Consecutive number