Workshop Manual
Table Of Contents
- Workshop Manual
- Table of contents
- 1 Foreword
- 2 General
- 3 User notes
- 4 Technical data
- 5 Job card overview
- 6 Job cards
- Removing and installing the crankcase bleeding
- Renewing the crankshaft sealing ring (opposite side to flywheel)
- Assembling/disassembling shaft sleeve on the crankshaft (opposite side to flywheel)
- Removing and installing the front cover (opposite side to flywheel)
- Checking the overhang of the cylinder liner
- Removing and installing the pressure holding valve
- Removing and installing the piston cooling nozzles
- Checking collar contact for cylinder liner
- Removing and installing the lubricating oil pan (metal sheet lubricating oil pan)
- Removing and installing the cylinder liner
- Testing the cylinder liner
- Removing and installing the V-belt, V-belt pulley
- Removing and installing torsional vibration damper (V-belt drive)
- Removing and installing the flywheel
- Removing and installing the crankshaft
- Checking the crankshaft
- Checking the axial clearance of the crankshaft
- Removing and installing the piston and con rod
- Checking the con rod
- Checking the piston
- Checking the piston rings and piston ring grooves
- Checking the compression pressure
- Removing and installing the cylinder head cover
- Removing and installing the exhaust return module
- Removing and installing the solenoid valve (exhaust gas return)
- Removing and installing cylinder head
- Checking piston overhang
- Removing and installing the valves
- Checking the valves
- Checking the valve guide
- Checking the valve lag
- Renewing the crankshaft sealing ring (flywheel side)
- Removing and installing the gearcase cover
- Removing and installing the camshaft
- Checking the camshaft
- Setting valve clearance (with or without removal of exhaust return module)
- Setting valve clearance (with exhaust return module installed)
- Removing and installing the rocker arm and rocker arm bracket
- Disassembling, assembling and checking the rocker arm and rocker arm bracket
- Removing and installing the lubricating oil cooler
- Removing and installing the lubricating oil cooler housing
- Removing and installing the oil suction pipe
- Removing and installing the control block
- Removing and installing the high-pressure pump (Installation position A)
- Removing and installing the high-pressure pump (Installation position B)
- Removing and installing the injector
- Removing and installing the fuel filter console
- Removing and installing the fuel supply pump (V-belt drive)
- Removing and installing the rail
- Removing and installing the pressure limiting valve
- Removing and installing the rail pressure sensor
- Removing and install the charge air line
- Removing and installing the coolant pump (V-belt drive)
- Removing and installing the thermostat
- Checking the thermostat (in the removed state)
- Removing and installing the thermostat housing
- Removing and installing the belt tensioner (V-rib belt)
- Removing and installing the fan drive
- Dismantling and assembling the fan drive
- Removing and installing the fan console (V-rib belt drive)
- Removing and installing the exhaust line
- Removing and installing the turbocharger
- Removing and installing the generator (V-belt drive)
- Removing and installing the starter
- Mounting engine on assembly block and demounting
- Removing and installing the engine mounting (elastic mounting)
- Removing and installing the cable harness
- Removing and installing the impulse transmitter (crankshaft)
- Removing and installing the impulse transmitter (camshaft)
- Removing and installing the pressure/temperature sensor (charge air)
- Removing and installing the oil pressure switch
- Removing and installing temperature transmitter (coolant)
- Removing and installing the fuel pressure sensor
- Installing and removing turning gear
- Installing and removing turning gear (Torsional vibration damper)
- Removing and installing the connection housing
- Check alignment of connection housing
- Removing and install the heating flange
- Removing and installing the glow plugs
- 7 Standard tools
- 8 Special tools
- Table of contents
3
© 02/2010 OBJ_DOKU-21740-001.fm
3/8
DEUTZ engines User notes
3.1 General
The documentation of the workshop manual has
been created based on the engine available at the
time of going to press.
There may be deviations in the descriptions, illustra
-
tions and parts due to further developments.
The maintenance work described in the operation
manual and in the workshop manual must be carried
out on schedule and completely. The maintenance
personnel must have the necessary technical
knowledge to perform the work. Safety and protec
-
tion 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 mainte
-
nance work.
Reference is made in the workshop manual job
cards to the regulations in chapter 3.2. These must
be read before working on the engine and must be
strictly followed.
The maintenance intervals and the work to be per
-
formed are specified in the maintenance schedule
of the operation manual. The job cards contain tech
-
nical documentation on the execution of mainte
-
nance work.
3.2 Specifications
3.2.1 Accident prevention and safety regula
-
tions
The legally prescribed rules for the prevention of ac
-
cidents must be observed. These are available from
professional associations or from dealers. These
are dependent on the application site, operating
mode and the operating and auxiliary materials be
-
ing used.
Special protection measures are specified depend
-
ing on the work being carried out, and are identified
in the job description.
Among other things it generally applies that:
● for the personnel:
– Only briefed personnel may operate or main
-
tain the engine. Unauthorised persons are
prohibited access to the machine room.
– Wear close-fitting clothing and ear protectors
in the machine room when the engine is in op
-
eration.
– Only deploy trained personnel to do repairs
and maintenance work.
– Do not work on the fuel system when the en
-
gine is running. The fuel system is under high
pressure - danger of death.
– Go to the workshop immediately in case of
leaks in the fuel system.
● for the engine room:
– Ensure adequate ventilation (do not cover air
shafts).
– Provide first aid kit and suitable fire extinguish
-
ers. Check the filling and readiness for opera
-
tion regularly.
– Only store inflammable materials in the ma
-
chine room if they are essential for operation
of the system.
– Smoking and naked flames are prohibited in
the machine room.
● for operation, maintenance and repairs on the
engine:
– Wait 30 seconds after switching off the engine
before working on the fuel sytem.
– After all work on the fuel system, it must be
bleeded - see the operation manual, chapter
"6 Fuel system“.
– Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
– Cleaning, maintenance and repair work may
only be performed with the engine at a stand
-
still and secured against starting.
– Injection lines and high pressure pipes must
not be deformed.