A. · 2019-07-26 · A. DEUTZ DEUTZ engines 3.1 General The documentation of the workshop manual...

A. DEUTZ Workshop Manual

competence level 2

TD 3.6 L4 TCD 3.6 L4

0312 3965 en

This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our written permission

A.

Regarding copyright questions and licensing agreements please contact :

VE-FL, Mr. Lippke Phone: +49 (0) 221 822-2599 E-mail: lippke.d@deutz com

DEUTZAG Information Systems Sales & Serv ice Ottostrar..e 1 D-51149 Kbln (Cologne) Phone: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 lnlernet: www.deutz.com E-mail: [email protected]

Printed in Germany All rights reserved

DEUTZ The engine company. 1st edition, © 0612012 Order no. 0312 3965 en

A. DEUTZ DEUTZ engines Foreword

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1 Foreword

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Foreword DEUTZ engines A. DEUTZ

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A© DEUTZ DEUTZ engines

• Read and observe the information in this documentation . 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 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 bears the sole risk.

• Use for the intended purpose also includes observance of the operating, maintena nee and repair 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 ava ilable 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 injury 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 spec ial tools and the ir perfect condition.

• Engine parts such as springs, clamps. elastic retaining rings etc. pose an increased risk of injury when handled incorrectly.

• The pertinent ru les for the prevention of accidents 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 .

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Foreword

• 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 modifications to the engine exclude manufacturer liability 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 variants ensures that the respective special requirements are met.

• The engine is equipped accord ing to the installation 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 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

OBJ DOKU-31076-00 1 frr.

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Foreword DEUTZ engines A. DEUTZ

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A. DEUTZ DEUTZ engines General

2 General

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A. DEUTZ DEUTZ engines

DEUTZ engines are the product of years of research and development. The profound expertise gained through this, in combination with high demands on quality, attests to the fact that our engines possess all the qualities of long life, high reliability and low fuel consumption. II goes without saying that the high environmental protection requirements are also met.

Maintenance and care are the only way the engine can satisfy the demands you make on it. Compliance with the prescribed maintenance limes and the careful execution of maintena nee and care work are therefore essential. Difficult operating conditions, deviating from normal operation, must be particularly heeded.

Please consult one of our service representatives responsible for operating faults and spare parts questions. Our trained specialist personnel ensures fast and professional repairs using original DEUTZ spare parts in the event of damage. Original spare parts from DEUTZ AG are always manufactured according to the state of the art.

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A. DEUTZ DEUTZ engines Safety information/ User information

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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, illustrations and parts due to further developments.

The valid documentations published by DE UTZ AG (for example Technical Circulars, Service Bulletins, etc.) must be observed.

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 pertorm 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.

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 performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

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3.2 Specifications

3.2.1 Accident prevention and safety regula-tions

The legally prescribed rules for the prevention of accidents 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 being used.

Special protection measures are specified depending 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 maintain 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 operation.

- Only deploy trained personnel to do repairs and maintenance work.

- Do not work on the fuel system when the engine 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 extinguishers. Check the filling and readiness for operation regularly

- Only store inflammable materials in the machine 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:

- The common rail systems used work with operating pressures up to approximately 2000 bar. In the case of potential faults, the pressure can even rise to significantly higher values before the pressure reducing valve opens.

- After shutting down the engine, wait at least 30 seconds before performing work on the fuel system. Depending on the version of common rail system, the fuel pressure in the common rail system will still not have dissipated after 30 seconds. The fuel pressure can permanently be several 100 bar.

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The fuel pressure here does not drop until the fuel system is opened and the fuel can escape.

- 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 standstill and secured against starting.

- Fuel lines, injection lines or fuel high-pressure lines must never be disconnected when the engine is running.

- Danger of injury ! The fuel jet can deeply penetrate the skin.

- Do not come close to the leakage area in the fuel high-pressure system with any body parts (for example hand).

- Always carry out an exact visual inspection of all high-pressure carrying components before tests on the running engine. Wear suitable protective clothing (for example goggles, gloves) for this. Leakages entail potential hazard sources for the workshop personnel.

- Even if no leakages can be discerned in the fuel high-pressure system, the workshop personnel should avoid the direct hazard zone or wear protective clothing (for example goggles, gloves) during tests when the engine is running and during the first test run.

- Always stay out of range of a fuel Jet, as it could cause severe injury.

- Fuel lines. injection lines and high-pressure lines must not be deformed.

- Damaged fuel lines. injection lines and highpressure lines must be replaced.

- Smoking is strictly prohibited when working on the fuel system.

- Do not work near to sparks and flames.

- Never disconnect an injector when the engine is running.

- Loosen screw connections slowly and not abruptly

- Open screw connections on the fuel system with extreme caution.

- After all work on the fuel system, it must be bleeded - see the operation manual, chapter "6 Fuel system".

3.2.2 Cleanliness instructions and measures for working with common rail systems

The common rail systems used in DEUTZ engines comprise high-precision components subjected to extreme loads. In view of the high-precision technology, ensure utmost cleanliness when working on the fuel system.

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Notes and measures to be observed before starting

work on the fuel system

• The fuel system must be closed. Make a visual inspection for leaks I damage to the fuel system.

• Clean the whole engine and engine room with the system closed before starting work on the fuel system.

• The engine must be dry when you start working on the fuel system.

• Blowing (dry) with compressed air is only permissible with the fuel system closed.

• When using a steam jet, first cover up the control unit. the cable plugs, all other electrical plug connections and the generator. Also, the steam jet may not be pointed directly at them.

• Electrical plug connections must be plugged when spraying.

• Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

• Only work on the fuel system in a clean environment (no dust. no grinding or welding). Avoid draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may be kept or operated in the same room.

• Air currents which kick up dust, such as those caused by brake repairs or the starting of engines, should be avoided.

• For work such as removal and installation on defective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out.

• No general machine tools may be operated in this room.

• Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised.

• Areas of the engine room from which particles of dirt could be loosened (for example the bottom part of the lipped driver cab) must be covered with fresh clean film.

• Working materials and tools must be cleaned before work. Only use tools without damage to 1he chrome plating or tools which are not chromeplated.

Notes and measures to be observed during work on the fuel system or with the fuel system open.

• Only work in clean overalls.


• Only lint-free cleaning cloths may be used for work on the fuel system.

• Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

• Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chromeplated.

• Do not use used cleaning fluid or test fluid for cleaning.

• Compressed air must not be used for cleaning on the open fuel system.

• Work on removed components may only be performed at a suitably equipped workbench.

• When removing and installing components. no materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

• Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.

• Openings on the components and on the engine must be closed immediately with suitable stoppers/caps.

• The stoppers/caps may only be removed immediately before installing.

• Store stoppers/caps free from dust and dirt in the original packaging and dispose of after using once.

• Only remove new parts from the original packaging Just before installation.

• Removed components must be kept in new, sealable bags or - if available - in the packaging of the new parts.

• Always use the original packaging of the new part to send back the removed components.

Notes and measures for the vehicle workshop area

• For work such as removal and installation on defective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out.

• The workshop floor is sealed or tiled.

• No welding gear, grinders, general machine tools, brakes or performance test benches may be operated in this room.

• Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating fans should be minimised.

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Noles and measures for workbench and tools in the vehicle hall

• A special workbench must be set up for work on removed components.

• Clean the removal and installation tools regularly and keep them in a closed tool cabinet.

• Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device.

• Working materials and tools must be cleaned before work. Only use tools wi1hout damage to the chrome plating or tools which are not chromeplated.

3.2.3 Additional information and measures for the handling of exhaust aftertreatment systems

• Basically all the same regulations and instructions up to and including chapter 3.2.2 must also be observed for work on exhaust aftertreatment systems!

• Utmost cleanliness must be observed for all work.

DPF (Diesel Particle Filter)

• The filter regeneration must be deactivated or, in systems with a filter regeneration prompt, not activated before performing service work.

• The duration of a full filler regeneration is 25 minutes on average. High exhaust temperatures occur in the exhaust system/on lhe end exhaust pipe independently of the actual load state of the engine (i.e. also during engine idling).

• No foreign bodies may get into the exhaust line or the combustion chamber. If this happens, the engine must be "run free" without diesel particle filter.

• Tensions and deformations of the shape of the Vbelt clip must be avoided . The DPF module may only be transported using the transport sleeves .

• V-belt clips and seals may not be reused (this also applies as soon as the screw connection has been loosened once).

Ignition system

• Caution! Dangerous high voltage. The ignition system operates with ignition voltages up to 10000 Volts.

• The ignition system must not be operated without a secondary load.

• Store the components in a dry and clean area.

• It is not permitted to store the components temporarily or stack them without their transport packaging.

• Components may only be stored and transported in the specified packaging.

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• Only remove new parts from the original packaging just before installation.

• Incorrectly operated or damaged components or parts that have been dropped must not be installed .

• Do not subject the components to any hard impacts or any other use of force.

• Faulty earthing, cable and plug connections can lead to malfunctions. Electronic components can be destroyed.

• Dirt and moisture on the primary and high voltage connections can cause malfunctions (leakage currant, misfiring, high voltage sp,'.Hks) .

• Check the protective caps of the ignition lines for discolouration, deformation and cracks before each usage.

SCR (Selective Catalytic Reduction)

• Ad Blue® is a caustic medium which causes heavy corrosion damage when it comes into contact with electronic components or similar.

• Leaks on the Ad Blue® pipes, the tank, the supply module and the feeding unit must be fixed immediately to avoid leakage of AdBlue®.

• Make sure the room is well ventilated .

• Contact with the skin should be avoided. Wear latex gloves if possible.

• Wash hands thoroughly before taking breaks and at the end of shifts.

• If the substance comes into contact with eyes, rinse thoroughly with water.

• If swallowed, rinse out mouth with a lot of water, drink plenty of water and seek medical advice.

• If discomfort or illness continues, seek medical advice.

• Product can pose danger of slipping if spilled. It is essential to remove spilled liquid. In so doing, ensure that the liquid does not enter the sewage system or ground/surface water. This means that the contamination should be physically removed and disposed of in suitable containers. Minimal amounts of remaining liquid may be rinsed away with a lot of water.

• The so-called lag time is application-dependent and may be up to 2 minutes in engines with an SCR system because the SCR pipes have to be pumped empty in this time.

3.2.4 Disposal regulations

The work described in !he operation manual and workshop manual necessitates renewal of parts and operating materials among other things. The renewed parts/ operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this.

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DEUTZ engines A. DEUTZ

Disposal includes recycling and the scrapping of parts/ operating materials, although recycling has priority.

Details of disposal and their monitoring are governed by regional, national and international laws and directives which the system operator must observe on his own responsibility.


3.3 Operation manual and workshop man-ual

In order to structure the information layout in a userfriendly way, the service documentation is divided into operating instructions and Job cards (workshop manual).

The operation manual contains a general description and instructions for all other maintenance work_

II 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 use of job cards (workshop manual) presupposes knowledge of the operating instructions content, this applying in particular for the service specifications. Repairs to the engine and components are described in the job cards (workshop manual), for the implementation of which more effort and correspondingly qualified experts are required.

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3.4 Job cards

The job cards are differentiated into "W" and "I" job cards. The "W' job card documents the standard repairs to the engine and/or its components. The necessary tools and special tools are also indicated in the "W" job card. The "I" job card also documents corresponding workflows for repairing the engine and/or its components. Special prerequisites must be fulfilled by the workshops for implementation of these workflows. For example, special tools and machine tools must be available.

3.4.1 Numbering of job cards

The job card numbering uses the format W 08-03-01. The individual parts of this formal are explained below:

• W 08-03-01: Documentation type

- W .... Workshop manual

- I ... .. . Repair manual

• W 08-03-01: Module

according to module list

• W 08-03·01: Component group

• W 08-03-01: Consecutive number

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3.4.2 Structure of a job card

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1. DEUTZ AG, publisher of service documentation

2. Number of associated spare parts list sheet (ETL)

3. Assembly - Designation

4. Numbering of the job cards

5. DEUTZ internal creation number

6. Title of job card

7. References/ Notes

8. Chapter

9. Graphic or photo

10. DE UTZ internal designation

11.Page number

12.Date of issue of job card

13.Note

14. Danger/ Important

15. Parts list/ Workflow

16.Auxiliary materials

17. Conventional tools, special tools

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DEUTZ engines

3.5 Explanation of symbols

Danger!

A. DEUTZ

of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury.

Caution! Danger to the componenVengine. Noncompliance can lead to destruction of the componenUengine. Must be observed!

Note General notes on assembly, environmental protection etc. No potential danger for man or machine.

Tool Conventional and special tools required for the work .

Auxiliary materials Working materials required in addition to the tools for performing the work (e.g. greases, oils. adhesives, sealants)

References to important documents

Reference within the workf1ow or to assemblies in which further documents or job cards are provided.

Test and setting data The necessary values are indicated here with link to a table within the job card.

Tightening specifications The necessary values are indicated here with link to a table within the job card.

A. DEUTZ

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Job card overview

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Job card overview Sorted alphabetically

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Activity Job card

Charge air line W 22-90-55

Charge air manifold W 22-90-54

Checking the thermostat (in the removed state) W 38-01-02

Closing parts W 02-90-01

Compensator structure (Exhaust line) W 41-90-21

Connection (Crankcase housing, exhaust gas circu-W 41-90-04

lation, coolant line)

Connection housing W 52-90-53

Console W 71-90-51

Drive components W 37-90-06

Engine mounting W 46-90-15

Engine mounting W46-90-15


Exhaust manifold (exhaust turbocharger) W 43-90-36



fuel filter W 20-90-17

Fuel line W 20-90-30

Fuel pre-filter W 20-90-16

Generator W 44-90-42


Holder W 09-90-09

Impulse transmitter (camshaft) W 51-90-20

Intake nozzle (exhaust turbocharger} W 22-90-35

Intermediate gear W 09-90-50

Line W 38-90-32

Line W 38-90-32

Line W 01-90-32

Line W 38-90-32

Line (Thermostat housing, exhaust gas circulation, W 41-90-32

coolant line)

Lubricant oil filter console W 15-90-38

Oil filling W 02-90-24

l· Oil measuring device W 01-90-23

Pressure fan W 39-90-52

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Module

Charge air line

Charge air line

Thermostat housing

Lubricating oil sump

Exhaust pipe

Exhaust gas recirculation

Connection housing

Exhaust gas treatment

Coolant pump

Engine mounting

Engine mounting

Engine mounting

Exhaust gas turbocharger



fuel filter

Fuel pipes

Fuel filter

Parts to generator

Parts to generator

Gearcase

Measuring instruments

Air intake pipe

Gearcase

Coolant pipes

Coolant pipes

Crankcase breather

Coolant pipes


Lubricating oil filler


Oil measuring device

Fan

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Activity

Pressure transmitter I temperature pressure trans-milter (charge air)

Removing and install the charge air line

Removing and installing charge air manifold

Removing and installing hydraulic pump drive

Removing and installing the belt tensioner (V-rib belt, level 1)

Removing and installing the connection housing





Removing and installing the console (V-rib belt. level 1)

Removing and installing the cylinder head cover

Removing and installing the exhaust line


Removing and installing the flywheel (Fastening parts)

Removing and installing the fuel line (injector, rail, high-pressure pump)

Removing and installing the gasket housing

Removing and installing the generator (Clamping latch)

Removing and installing the generator (Fastening parts)

Removing and installing the glow plugs

Removing and installing the high-pressure pump

Removing and installing the injector

Removing and installing the lubricating oil cooler

Removing and installing the lubricating oil line (ex-haust turbocharger)

Removing and installing the lubricating oil line (ex-haust lurbocharger)

Removing and installing the lubricating oil pan

Removing and installing the lubricating oil return line (exhaust turbocharger)


Removing and installing the oil suction pipe

Job card

W 22-90-20

W 22-01-01

W 22-04-01

W 83-02-01

W 44-01-01

W 52-01-01

W 52-01-01

W 52-01-01

W 52-01-01

W 52-01-01

W 44-02-06

W 08-01-01

W41-01-01

W 41-01-01

W 05-03-01

W 21-05-05

W 01-03-01

W 44-02-01

W 44-02-01

W 63-02-01

W 17-01-04

W 19-01-01

W 15-02-01

W 16-04-01

W 16-04-01

W 02-01-01

W 16-05-01

W 16-05-01

W 16-01-01

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Module

Charge air line

Charge air line

Charge air line

Hydraulic pump drive

Add-on parts

Connection housing

Connection housing

Connection housing

Connection housing

Connection housing

Add-on parts

Cylinder head cover

Exhaust pipe

Exhaust pipe

Flywheel

Fuel pipes

Crankcase

Generator

Generator

Start aid

High-pressure pump

Injector

Lubricating oil cooler

Lubricating oil pipe





Oil suction pipe

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Activity Job card

Removing and installing the rail W 21-04-01

Removing and installing the starter W 44-03-01

Removing and installing the starter W 44-03-01

Removing and installing the thermostat W 38-01-01

Removing and installing the transfer line W 01-07-05

Removing and installing the turbocharger W 43-01-01

Removing and installing the turbocharger W 43-01-01

Renewing the crankshaft sealing ring (flywheel side) W 01-02-01

Supply pump (Fuel) W 20-90-47

V-rib belt pulley W 37-90-13

V-rib belt pulley W37-90-13

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Module

Fuel pipes

Starter

Starter

Thermostat housing

Crankcase



Crankcase

Fuel supply pump

Coolant pump

Coolant pump

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5.2 Sorted numerically

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Job card overview Sorted numerically

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Job card Activity

W 01-02-01 Renewing the crankshaft sealing ring (flywheel side)

W 01-03-01 Removing and installing the gasket housing

W 01-07-05 Removing and installing the transfer line

W 01-90-23 Oil measuring device

W 01-90-32 Line

W 02-01-01 Removing and installing the lubricating oil pan

W 02-90-01 Closing pans

W 02-90-24 Oil filling

W 05-03-01 Removing and installing the flywheel (Fastening parts)

W 08-01-01 Removing and installing the cylinder head cover

W 09-90-09 Holder

W 09-90-50 Intermediate gear

W 15-02-01 Removing and installing the lubricating oil cooler

W 15-90-38 Lubricant oil filter console

W 16-01-01 Removing and installing the oil suction pipe

W 16-04-01 Removing and installing the lubricating oil line (ex-haust turbocharger)

W 16-04-01 Removing and installing the lubricating oil line (ex-haust turbocharger)

W 16-05-01 Removing and installing the lubricating oil return line (exhaust turbocharger)

W 16-05-01 Removing and installing the lubricating oil return line (exhaust turbocharger)

W 17-01-04 Removing and installing the high-pressure pump

W 19-01-01 Removing and installing the injector

W 20-90-16 Fuel pre-filter

W 20-90-17 Fuel filter

W 20-90-30 Fuel line

W 20-90-47 Supply pump (Fuel)

W 21-04-01 Removing and installing the rail

W 21-05-05 Removing and installing the fuel line (iniector, rail, high-pressure pump)

W 22-01-01 Removing and install the charge air line

W 22-04-01 Removing and installing charge air manifold

W 22-90-20 Pressure transmitter I tempera tu re pressure trans-milter (charge air)

W 22-90-35 Intake nozzle (exhaust turbocharger)

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Module

Crankcase

Crankcase

Crankcase


Crankcase breather




Flywheel

Cylinder head cover

Gearcase

Gearcase

Lubricating oil cooler

Lubricating oil filter

Oil suction pipe





High-pressure pump

Injector

Fuel filter

Fuel filter

Fuel pipes

Fuel supply pump

Fuel pipes

Fuel pipes

Charge air line

Charge air line

Charge air line

Air intake pipe

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Job card Activity

W 22-90-54 Charge air manifold

W 22-90-55 Charge air line

W 37-90-06 Drive components

W 37-90-13 V-rib belt pulley

W 37-90-13 V-rib belt pulley

W 38-01-01 Removing and installing the thermosta1

W 38-01-02 Checking the thermostat (in the removed state)

W 38-00-32 Linc

W 38-90-32 Line

W 38-90-32 Line

W 39-90-52 Pressure fan

W 41-01-01 Removing and installing the exhaust line

W 41-01-01 Removing and installing the exhaust line

W 41-90-04 Connection (Crankcase housing, exhaust gas circu-lation, coolant line)

W41-90-21 Compensator structure (Exhaust line)

W 41-90-32 Line (Thermostat housing, exhaust gas circulation , coolant line)

W 43-01-01 Removing and installing the turbocharger

W 43-01-01 Removing and installing the turbocharger

W 43-90-36 Exhaust manifold (exhaust turbocharger)



W 44-01-01 Removing and inslalling the belt tensioner (V-rib belt, level 1)

W 44-02-01 Removing and installing the generator (Fastening parts)

W 44-02-01 Removing and installing the generator (Clamping latch)

W 44-02-06 Removing and installing the console (V-rib belt, level 1)

W 44-03-01 Removing and installing the starter

W 44-03-01 Removing and installing the starter

W 44-90-42 Generator

W 44-90-42 Generator

W 46-90-15 Engine mounting



©:J9il.lJ1l 10/12

A. DEUTZ

Module

Charge air line

Charge air line

Coolant pump

Coolan1 pump

Coolant pump

Thermostat housing

Thermostat housing

Coolant pipes

Coolant pipes

Coolant pipes

Fan

Exhaust pipe

Exhaust pipe


Exhaust pipe







Add-on parts

Generator

Generator

Add-on parts

Starter

Starter

Parts to generator

Parts to generator

Engine mounting

Engine mounting

Engine mounting

A. DEUTZ

Job card Activity

W 51-90-20 Impulse transmitter (camshaft)

W 52-01-01 Removing and installing the connection housing





W 52-90-53 Connection housing

W 63-02-01 Removing and installing the glow plugs

W 71-90-51 Console

W 83-02-01 Removing and installing hydraulic pump drive

11 /12

Module


OBJ_DOKU-31079-001 .frn

Measuring instruments

Connection housing

Connection housing

Connection housing

Connection housing

Connection housing

Connection housing

Start aid

Exhaust gas treatment


II

II

Job card overview Sorted numerically OBJ_DOKU-31079-001.tm

© 0912012

A. DEUTZ

12/12

A. DEUTZ DEUTZ engines Job cards

OSJ_DOKU-31080-001.frn

6 Job cards II

© 0912012 1/2

Job cards DEUTZ engines A. DEUTZ

OBJ_ DOKU-31080-001 .fm

II

©0912012 2/2

A. DEUTZ

Renewing the crankshaft sealing ring (flywheel side)

[I] Standard tools

Special tools: - Pricker 01899103 - Assembly lever 01899110 - Assembly tool 02992214

~ - Self-tapping screw - Washer

Removing the crankshaft sealing ring

Gasket housing

2 Shaft sealing ring

3 Hexagon head screw

188 Packing compound

• Remove flywheel.

__::__; Module 05

• Make a hole of approximately 3 mm in the crankshaft sealing ring with a pricker.

~ Attention! ~ Do not damage the gasket housing and

crankshaft!

©091~!)12 1/4

Crankcase W 01-02-01


<::/5051d-~

al< 7083-1

II

II

Crankcase W 01-02-01 OBJ_DOKU-31081-001 .fm

• Screw in a self-tapping screw ( 1) with washer,

•Pullout the crankshaft sealing ring with assembly lever.

~ Ensure that the crankshaft does not get

EJ damaged.

• Visually inspect the crankshaft sealing ring running surface .

Installing the crankshaft sealing ring

• Mount guide sleeve ( 1).

• Tighten screws (2) .

~ The bores in the guide sleeve must match ~ the threaded holes in the crankshaft

flange.

iJ C9,'2012 2/4

I , • L

C

A. DEUTZ

•

-.

' '

A. DEUTZ

• Place the crankshaft sealing ring carefully on the peripheral surface.

~ Do not oil waxed crankshaft sealing rings.

E_J The sealing lip faces the crankcase.

• Mount assembly sleeve { 1 }.

• Press on the crankshaft sealing ring to the stop.

• Plug in the bearing (2).

• Screw on nut (3).

• Tighten nut to the stop of the assembly sleeve { 1 ).

r:;;:i The installation depth is determined by the EJ assembly tool.

• Remove assembly tool.

• Install flywheel.

CJ Module 05

(1) 09/2012 3/4

L

•

_)

0


OBJ_00 KU-31 081-001 .fm

© 47089-1

•

..

~

• () •7091·1

II

II

Crankcase W 01-02-01 OBJ _OOKU-31 081-001.lm

©0912012

A. DEUTZ

414

Removing and installing the gasket housing

Standard tools: - Splint driver

- Packing compound DEUTZ OW 67

Removing the gasket housing

1

2

Gasket housing

Shaft sealing ring




L.:j·· Module 05

• Remove connection housing.

G Module 52

• Remove lubricating oil pan.

CJ Module 02

• Unscrew all screws (1 ).

• Remove gasket housing (2).

©0912012 114


OBJ_DOKU-31082 001.frn

© 50518-0

II

II

Crankcase W 01-03-01 OBJ_DOKU-31082-001 .fm

• Knockout crankshaft sealing ring (1 ).

It@ Attention! li2J Do not damage the sealing surfaces.

• Visually inspect the components.

Installing the gasket housing

• Clean sealing surfaces.

• Apply sealing compound (1) evenly on the sealing surface.

bl Sealing cord strength approx. 0.5 -EJ 0.6mm.

• Mount gasket housing.

• Tighten screws ( 1 ).

30912012 214

A. DEUTZ

0 50520 0

!.: 50521 0

A. DEUTZ

The sealing face (arrows) must be flush with the oil pan sealing face.

• Tighten the screws according to the tightening sequence.

!'!,·. 20 Nm

• Renew crankshaft sealing ring (flywheel side). ~ ---. ~

,__ . Module 01

• Install lubricating oil pan.

/ ___ / Module 02

• Install connection housing.

,: _ _ } Module

• Install flywheel. I / •-: Module

52

05

3/4



II

II

Crankcase W 01-03-01 OBJ_DOKU-31082-001. Im

Technical Data

Tightening specifications

ID no. Name

A01 095 Gasket housing on crank.case

A. DEUTZ

Screwtvoe Notes / Remark Value Observe tightening sequence

20 Nm

For 1he tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of+/- 10% is permissible.

4/4

A. DEUTZ

Removing and installing the transfer line

Standard tools


Removing the transfer line

1 Transfer line

2 Torx screw

3 Screw plug



L) Module 02

• Unscrew screws ( 1).

• Remove transfer line (2).

• Visually inspect the component.

©0912012

35 Nm

114



© 50~2~-0

II

II

Crankcase W 01-07-05 OBJ_DOKU-31083-001.fm

Installing the transfer line


~ Attention! L...i2J No packing compound must get into the oil

channel (1 )!

• Apply sealing compound (1) evenly on the sealing surface.


• Mount transfer line (1 ).

• Tighten screws (2).

-'"'· -:., 20Nm

• Install lubricating oil pan .

...:....} Module 02

214

A. DEUTZ

\ .. ( . ., e 50723-1

0

©51276-0

A. DEUTZ

Technical Data


ID no. Name A01 016 Transfer line on crankcase

Screw e Notes / Remark


OBJ_DOkU-31083-001 fm

Value 20 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of+/. 10% is permissible.

3/4

II

II

Crankcase W 01-07-05 OBJ_DOKU-31083-001.fm

A. DEUTZ

4/4

A. DEUTZ


[1J Standard tools

Oil dipstick

2 Ball

3 Stopper

4 Guide tube

5 0-ring

IIJ@rl Use new round sealing ring.

© U912012 1/2

Oil measuring device W 01-90-23

OBJ_DOKU-31084-001 .Im

.: 50392·0

II

II

Oil measuring device W 01-90-23 0BJ_DOKU-31084-001 .Im

'9 0912012

A. DEUTZ

2/2

A. DEUTZ

Line

rn Standard tools

Pipe clip

2 Pipe

3 Spring band clip

4 Rubber sleeve

5 Intake nozzle

6 Spring band clip


©0912012

8 Nm

1/2

Crankcase breather W 01-90-32


5

© 50658·0

II

II

Crankcase breather W 01-90-32 OBJ_DOKU-31085-001 Jm

© 091.2012

A. DEUTZ

2/2

A® DEUTZ

Lubricating oil sump W 02-01-01

OBJ_DO KU-31086-001 .fm

Removing and installing the lubricating oil pan

[]] Standard tools

Special tools: - Separating tool


02992301

Removing the lubricating oil pan

Lubricating oil pan

2 Nut 3 Torx screw


• Drain lubricating oil, collect and dispose of according to regulations.

• Unscrew all screws (arrow).

• Remove lube oil tray (1).

1 /6

• ' I

I

•

Attention! Make sure that no gasket residue falls into the crankcase. Seal all openings .

Collect leaking operating substances in suitable vessels and dispose of according to regulations .

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

244

2

4 t,512860

• • • • • ' - r l

,

l J

-·-~·--· 11

1

• • •

II

II

Lubricating oil sump W 02-01-01 OBJ_DOKU-31086-001.fm

• Drive in separating tool (1) to the stop (2) .

Attention! The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces .

• Drive in second separating lool ( 1) to the stop (2).

Attention! The tool can only be driven in in the area of the crankcase. Separation in the area of aluminium parts is not allowed. Do not damage the sealing surfaces.

• Lever out lubricating oil pan .


© 0912012 216

A. DEUTZ

©51290-0

A. DEUTZ

Installing the lubricating oil pan

• Scrape off sealing compound with separating tool .

ltW Attention! t0 Wear protective glasses.

• Clean the sealing surface on the crankcase with a wire brush.

r:=;;:::i The sealing surfaces must be dry and free ~ from grease and dirt.

ltW Attention! t0 Wear protective glasses.

• Clean the sealing surface on the lubricating oil pan with a wire brush .

~ The sealing surfaces must be dry and free ~ from grease and dirt.

• To align the lubricating oil pan, screw four pin bolts ( 1} diagonally opposed into the crankcase.

3/6

I ij _q :ll - --- -I • • • I I .

'•· ~~~-- -· . .

I



;; 51292-C

--L~ - ~~ . C - ,

II

II

Lubricating oil sump W 02-01-01 OBJ_DOKU-31086-001 fm


r.:;;;i The sealing surfaces must be dry and free L'.:::_J from grease and dirt.

• Apply packing compound to the joints (arrows).

• Apply packing compound evenly to the sealing surface.

• Align the lubricating oil pan in the appropriate installation position with the pin bolts.

• Mount lubricating oil pan.

Attention! Do not move the lubricating oil pan any more. Observe the drying time for the packing compound.

• Unscrew the pin bolts.

• Fasten all screws (1).

©0912012 4/6

• • I

r

• • -I~

'~\ T 0

A. DEUTZ

© 51:/93-0

© 51294-0

l 1 ,

• ,. •

J I

• • •• •· • ., @ 51295-0

A. DEUTZ


!P,r~ 20 Nm

• Fill in lubricating oil according to operating manual.

~ 0912012 5/6



14 13 1 2 3 4 5 15 16

© 51296-0 II

II

Lubricating oil sump W 02-01-01 OBJ_DOKU-31 086-001 .Im

Technical Data


ID no. Name

A02 030 Lubricating oil pan on crankcase

Screwtvpe

A. DEUTZ

Notes / Remark Value Observe lightening

20 Nm sequence!

For the tightening procedure according to torque using a torque wrench, a maximum varlation of the tightening torque of+/- 10% is permissible.

© 0912012 6/6

A. DEUTZ

Closing parts rn Standard tools

1 Screw plug 55 Nm

2 Sealing ring

1~1 Use a new sealing ring.

©0912012 1/2



Collect draining lubricating oil and dispose of properly.

© 50331-0

II

II

Lubricating oil sump W 02-90-01 OBJ_DOKU-31087-001.fm

© 09!:?0'i.2

A. DEUTZ

212

A. DEUTZ

Oil filling

[I] Standard tools

1 Oil filler pipe

2 Hexagon head screw 30 Nm

3 Filler lock

4 Seal

5 Screw plug 95 Nm

l~ I Use a new gasket.

:!;l 0912012 1/2


OBJ_D0 KU-31 068-001 .fm

© 50668-0

II

II

Lubricating oil sump W 02-90-24 OBJ DOKU-31088-001 .fm

A. DEUTZ

2/2

A. DEUTZ

Removing and installing the flywheel (Fastening parts)

[I] Standard tools

Special tools: - Guide pin (self-const

ructed) - Auxiliary screws - Rotation angle disc

Removing the flywheel

Flywheel

2 Ring gear

3 Screw

4 Bearing bush

M10x120 01899093

• Hold the crankshaft at the central screw.

• Screw in auxiliary screws ( 1 ).

• Unscrew screws (2).

• Remove flywheel using auxiliary screws .


©0912012 1/4

Flywheel W 05-03-01


© 51460-0

~ 5M62-U

II

II

Flywheel W 05-03-01 OBJ_DOKU-31089-001 .fm

Installing the flywheel

• Insert self-made guide pin (arrow) .

bl The bores in the flywheel must match the EJ threaded bores in the crankshaft flange.

• Mount flywheel using auxiliary screws.

~ Attention! Lf£J Renew screws every time they are loo

sened.

• Tighten screws alternately.

- Stage 1:

,~e·,c.:, 30 Nm

• Tighten screws with rotation angle disc.

- Stage 2:

- Stage 3

i"'r'•:, 30"

• Remove guide pin.

• Unscrew auxiliary screws.

© 0912012

A. DEUTZ

2/4

A. DEUTZ

Technical Data


ID no. Name

A05 001 Flywheel on crankshaft

A05 001 Flywheel on crankshaft A05 001 Flywheel on crankshaft

Screw type Notes / Remark Stage 1: Use new screws Stage 2:

Stage 3:

Flywheel W 05-03-01

OBJ_DOKU-31089-001 Jm

Value

30 Nm

60° 30°

For the tightening procedure according to torque using a torque wrench. a maximum variation of the lightening torque of +/- 10% is permissible.

© 091201:? 3/4

II

II

Flywheel W 05-03-01 OBJ_DOKU-31089-001 fm

11: 09120',2

A. DEUTZ

4/4

A. DEUTZ

Removing and installing the cylinder head cover

[I] Standard tools

Removing cylinder head

Cylinder head cowling

2 Seal

3 Screw

4 Filler lock

5 Plug piece

• Removing the crankcase breather.

L,:} Module 01

• Unscrew screws ( 1 ).

• Remove cylinder head cowling (2).

1/4

Cylinder head cover W 08-01-01

OBJ_DOKU-31090-001 fm

II

II

Cylinder head cover W 08-01-01 OBJ_OO KU-37090-001 .fm

• Remove gasket ( 1 ).

Installing cylinder head cover.

• Mount new gasket (1) .

• Mount cylinder head cover (1) .

A. DEUTZ

~ 50509 0

G 50509-0

2/4


§,"•~ 8.5 Nm

• Install crankcase breather.

W Module 01

©0912012 3/4

4

Cylinder head cover W 08-01-01

OBJ_DOKU-31 090-001. fm

5

© 50511-0 II

a

Cylinder head cover W 08-01-01 OBJ_DOKU-31090-001 .fm

Technical Data


ID no. Name Screw e Notes/ Remark A08 004 Cylinder head cover on cylinder head

A. DEUTZ

Value 8.5Nm

For the lightening procedure according to torque using a torque wrench. a maximum variation of the tightening torque of+/- 10% is permissible.

4/4

~>® DEUTZ

Holder

[1] Standard tools

1 Holder

2 Impulse transmitter

3 Hexagon head screw 8.5 Nm 4 Hexagon head screw 5 Nm

Position 2:

1~ I Use new round sealing ring.

~ 0912012 1/2

Gearcase W 09-90-09

OBJ_0OKU-31091-001 fm

- Safety information / User information

Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt particles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling.

~51285-0

II

II

Gearcase W 09-90-09 OBJ DOKU-31091-001 ,lm

A. DEUTZ

212

A. DEUTZ

Intermediate gear

[I] Standard tools

1 Intermediate gear

2 Shaft


©091201:/

30 Nm

112

Gearcase W 09-90-50

OBJ _DOKU-31 092-001.fm

II

II

Gearcase W 09-90-50 06J_D0K U-31092-001 fm

© 09120" 2

A. DEUTZ

2/2

A. DEUTZ

Lubricating oil cooler W 15-02-01

OBJ_DO KU-31093-001.fm

Removing and installing the lubricating oil cooler

[]] Standard tools

Removing the lubricating oil cooler

1 Lubricating oil cooler

2 Seal


• Unscrew all screws ( 1 ).

• Remove lubricating oil cooler (2).

• Remove gasket (3).

r:;;i Collect draining lubricating oil and dispose EJ of property.


~ 09/2012

. (

(

1/4

Collect leaking operating substances in suitable vessels and dispose of according to regulations. The appropriate operating manual should be observed for emptying and filling the engine.

~ 5C279 0

II

II

Lubricating oil cooler W 15-02-01 OBJ_DOKU-31093-001.fm

Installing the lubricating oil cooler



• Turn in screws (arrows).

M8x20-10.9

• Fasten new seal (1) on lubricant oil cooler housing with screws.

• Mount lubricating oil cooler ( 1 ).

• Tighten screws (2)

• Tighten all screws (2) alternalely .

.-"'" • ·. 30 Nm

2/4

A. DEUTZ

I:: 50280·0

~)5C2S1-0

A. DEUTZ

Technical Data


ID no. Name A 15 051 Oil cooler housing on crankcase


Lubricating oil cooler W 15-02-01

OBJ_DOKU-31093-001 fm

Value 30 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3/4

II

II

Lubricating oil cooler W 15-02-01 OBJ_DOK U-31 093-001.fm

:al 09120"2

A. DEUTZ

4/4

A. DEUTZ

Lubricant oil filter console

[I) Standard tools

1 Interchangeable filter 12 Nm

2 Threaded bush

3 Cover

4 0-ring


,~, Use new round sealing ring.

1/2

5

Lubricating oil filter W 15-90-38


Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Observe the appropriate operating instruc• lions for emptying and filling the engine.

·1 "'l

( ;, -~

l q JQ• '~~

•

lP' • 2

:;;, 50390-0

II

II

Lubricating oil filter W 15-90-38 OBJ_DOKU-31094-001 .frn

A. DEUTZ

2/2

A. DEUTZ

Removing and installing the oil suction pipe

Standard tools

- Packing compound DEUTZ DW 73

Removing the oil suction pipe

1 Oil suction pipe

2 Torx screw



!..._:j Module 02


• Remove oil suction pipe (2).


©0912072 1/4

Oil suction pipe W 16-01-01

O8J_DOKU-31095-001.fm

G) 5()409-0

II

II

Oil suction pipe W 16-01-01 OBJ_DOKU-31095-001.frn

Installing the oil suction pipe

• Clean sealing surface.

• Apply 5ealing compound (1) evenly on the sealing surface.

• Clean sealing surface.

• Install oil suction pipe ( 1 ).


!'!• ,.·.:·, 22 Nm

• Install lubricating oil pan.

~ 1 Module 02

©09R01Z 214

A. DEUTZ

I © 50727-0

A. DEUTZ

Technical Data


ID no. Name A16 015 Oil suction pipe on crankcase

Screw e Notes / Remark M8x25-10,9

Oil suction pipe W 16-01-01


Value 22 Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of+/- 10% is permissible.

© OQ/2012 314

II

II

Oi I suction pipe W 16-01-01 OBJ_DOKU-31095-001 ,fm

A. DEUTZ

414

A. DEUTZ

Removing and installing the lubricating oil line ( exhaust turbocharger)

[1] Standard tools

Removing the lubricating oil line

1 Lubricating oil line

2 Hollow screw

3 Sealing ring

• Unscrew hollow screw ( 1 }.

• Remove sealing rings (2).

©09/2012 1/4

Lubricating oil pipe W 16-04-01



Observe the appropriate operating instruc· lions for emptying and filling the engine.

© 5{)444-0

II

II

Lubricating oil pipe W 16-04-01 OBJ_DOKU-31096-001.lm

• Unscrew hollow screw ( 1 ).


• Remove lubricating oil pipe (3).

Installing the lubricating oil line


• Mount lubrication oil line ( 1 ).

• Mount sealing rings (2).

• Screw on hollow screw (3).


• Mount lubrication oil line (1 ).

• Mount sealing rings (2) .

• Tighten hollow screw (3).

18 Nm

Attention! Install tension-free.

©:)9/2012

A~ DEUTZ

214

• Tighten hollow screw ( 1 ).

!'!'·,::: 18 Nm

ltW Attention! ~ Install tension-free.

(;)0912012 314



II

II

Lubricating oil pipe W 16-04-01 OBJ_DOKU-31096-001 fm

Technical Data


ID nQ. Name

A43 047 Lubricating oil pipe on exhaust tur-bocharQer

A43 048 Lubricating oil line on crankcase

A. DEUTZ

Screw tvoe Notes / Remark Value

Hollow screw Use new sealing rings 18 Nm

Hollow. screw Use new sealing rings 18 Nm


4/4

A. DEUTZ

Removing and installing the lubricating oil line (exhaust turbocharger)

[I] Standard tools

Removing the lubricating oil line

1 Lubricating oil line

2 Hollow screw

3 Sealing ring

• Unscrew hollow screw (1) .


G) 0912012 114




Observe the appropriate operating instructions for emptying and filling the engine.

©50t56·U

© 50675-0

II

II

Lubricating oil pipe W 16-04-01 OBJ_DOKU-31097-001,lrn

• Unscrew hollow screw (1).

• Remove sealing rings (2) .

• Remove lubricating oil pipe (3).

Installing the lubricating oil line


• Mount lubrication oil line ( 1 ).

• Mount sealing rings (2).

• Screw on hollow screw (3).

• Clean sealing surfaces .

• Mount lubrication oil line (1 ).

• Mount sealing rings (2) .

• Tigh1en hollow screw (3).

18 Nm

Attention! Install tension-free.

A. DEUTZ

:;l 50676-C

2/4

A. DEUTZ

• Tighten hollow screw (1 ).

~ Attention! L..i2J Install tension-free.

© 09,2012 314


OBJ DOKU-31097-001.fm

II

II


Technical Data


ID no. Name

A43 047 Lubricating oil pipe on exhaust tur-bocharger

A43 048 Lubricating oil line on crankcase

A. DEUTZ

Screw type Notes / Remark Value

Hollow screw Use new sealing rings 18 Nm

Hollow screw Use new sealing rinos 18 Nm

For the tightening procedure according to torque using a torque wrench. a maximum variation of the tightening torque of +/- 10% is permissible.

()0912012 4/4



Removing and installing the lubricating oil return line ( exhaust turbocharger)

Standard tools

Special tools: - Disassembly tool

- Fitting compound DE UTZ AP1908

Removing the oil return line

1 Fastening flange

2 0-ring

3 Oil return line

4 0-ring



7 Seal

• Unscrew screws ( 1).


02992127

116



© 50435-0

II

II

Lubricating oil pipe W 16-05-01 OBJ_OOKU-31098-001 .lm

• Unscrew screw (1).

• Pull out oil return line (2) in direction of arrow.

• Remove flange ( 1) in direction of arrow.

• Remove round sealing ring (2) with disassembly tool.


• Remove the O-ring (1) with the disassembly tool .


216

A. DEUTZ

0

0 © 50683-C

A. DEUTZ

Mounting the oil return line


• Lightly coat new round sealing ring with DE UTZ AP1908 mounting compound.

• Insert new O-ring { 1 ).


• Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound.

• Insert new O-ring (1) .

• Insert flange (2) in direction of arrow.


• Mount oil return pipe { 1 ).

• Insert oil return line ( 1) in direction of arrow.

• Fas ten screw (2).

0

316


OBJ _DOKU-31098-001.fm

© 5068•-0 II

II

Lubricating oil pipe W 16-05-01 0BJ_DOKU-31098-001 Im


• Mount gasket ( 1 ).

• Mount oil return pipe (2).


Bt· '::-, 8.5 Nm

• Tighten screw (1 ).

,",r· •· . 8.5 Nm

ffil Attention' l.J2j Install tension-free.

A. DEUTZ

4/6

A. DEUTZ

Technical Data


ID no. Name

A43 044 Oil return line on exhaust turbochar-

Icier A43 046 Oil return line on crankcase

Screw type Notes/ Remark



Value

8.5 Nm

8.5 Nm


5/6

II

II

Lubricating oil pipe W 16-05-01 OBJ_DOKU-31098-001 Im

© 09<2012

A® DEUTZ

6/6

A. DEUTZ


OBJ_DOKU-31 099-001.fm


[I] Standard tools

Special tools: - Disassembly tool

- Fitting compound DE UTZ AP1908

Removing the oil return line

Fastening flange

2 O-ring

3 Oil return line

4 O-ring



7 Seal

• Unscrew screws (1 ).


02992127

1/6



0 ..,..... 4

rs; 50657 •0

II

II

Lubricating oil pipe W 16-05-01 OBJ_DOKU-31099-001 .fm

• Unscrew screw ( 1).

•Pullout oil return line (2) in direction of arrow.

• Remove flange ( 1) in direction of arrow.

• Remove round sealing ring (2) with disassembly tool.


• Remove the O-ring (1) with the disassembly tool.


©U9.12Q12 2/6

A. DEUTZ

© 506B1-0

0 © snnBJ-o

A. DEUTZ

Mounting the oil return line


• Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound .

• Insert new O-ring ( 1 ).


• Lightly coat new round sealing ring with DEUTZ AP 1908 mounting compound.

• Insert new O-ring (1 ).

• Insert flange (2) in direction of arrow.


• Mount oil return pipe ( 1 ).

• Insert oil return line (1) in direction of arrow.

• Fas ten screw (2).

3/6

l I

01



© 50684-0

I., 0 .:; 5068.5-0

~ 50686·0

II

II




• Mount oil return pipe (2).


:''· ,_., 8.5 Nm

• Tighten screw (1 ).

f,-, :; 8.5 Nm

liN Attention! li2J Install tension-free.

© 0912012

A. DEUTZ

© 50688-D

4/6

A. DEUTZ

Technical Data


ID no. Name

A43 044 Oil return line on exhaust turbochar-ger

A43 046 Oil return line on crankcase

Screw type Notes/ Remark


OBJ_DO KU-31 099-001.fm

Value

8.5 Nm

8.5 Nm


© 0912012 5/6

II

II

Lubricating oil pipe W 16-05-01 OBJ DOKU-31099-001 fm

,:;J 0912012

A. DEUTZ

6/6

A. DEUTZ

High-pressure pump W 17-01-04


Removing and installing the high-pressure pump

w Standard tools: - Separating tool

Special tools: - Special wrench 02992112 - Disassembly tool 02992127 - Plugs/caps 01899144

~ - Mirror - Marker pen, waterproof,

permanent

Removing the high-pressure pump

1 High-pressure pump

2 Spacer

3 Hexagonal nut

4 Washer

5 O-ring

6 Hexagonal nut

7 O-ring

©09/:2012 116

- Safety information/ User information

Danger! Do not carry out work on the fuel system when the engine is running . The fuel system is under high pressure -Danger of death.

The fuel pressure can continuously remain up to several 1 OD bar even after stopping the engine. Here the fuel pressure is only reduced if the fuel system is opened and the fuel can escape outside.

Attention! Ensure utmost cleanliness for all work. Remove any paint residue and din particles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling . Collect leaking operating substances in suitable vessels and dispose of according to regulations.

J '. u

'., ·• .. -'~':f°'~ ' ...

3

II

II

High-pressure pump W 17-01-04 OBJ_DOKU-31100-001 .lm

• Unlock cable plug and remove.

• Remove high-pressure line .

• Remove fuel pipes.

[ __ J Module 21

• Unscrew locking screw (1 ).

• Remove sealing ring .

L:} Module 09

• Turn crankshaft in engine direction of rotation until marking is visible.

(1) Marking high-pressure pump gear wheel

• Apply help marking ( 1 ).

High-pressure pump gear wheel and intermediate gear

ir6:7 Attention! LJ2j Do not turn the crankshaft any more'

2/6

A. DEUTZ

• Unscrew nuts ( 1 ).

~ Attention! ~ Do not twist the high-pressure pump.

• Remove high-pressure pump (2).

~ Attention! lJ2j Do not turn the crankshaft any more!

Attention! Do not damage the high-pressure pump gear wheel.

Use a suitable tool.

• Hold high-pressure pump gear wheel (1 ).

• Unscrew nut (2) .

• Remove washer (3).

• Pull off high-pressure pump gear wheel ( 1) with separating tool.

• Remove spacer (4) .


• Remove the O-rings ( 1) with the disassembly tool.

Attention! All the help markings must be transferred when renewing/changing a part. Do not turn the crankshaft any morel

3/6

High-pressure pump W 17-01-04

OBJ_DOKU-31100-001 Im

II

II

High-pressure pump W 17-01-04 0BJ_DOKU-31100-001.fm

Installing the high-pressure pump


• Mount new O-rings ( 1 ).

• Push on spacer (2).

Attention! Ensure that the installation location is free from faults. Recess (3) is on the fuel supply side.

• Mount high-pressure pump gear wheel ( 1 ).

liW Attention! LJ2:..j Pay attention to installation position.

(2) Surrounding groove

(3) Marking

Attention! Ensure that the installation location is free from faults. Do not damage the high-pressure pump gear wheel. The clamping pin ( 1) must engage in the groove (2).

• Fit washer (3).

• Screw on nut (4). 1~1 Use a suitable tool.

• Hold high-pressure pump gear wheel (5).

• Tighten nuts (4)

"',-. 80Nm

© 0912012

A. DEUTZ

© 51436-0

© 51438-0

416

A® DEUTZ

e pump H h-pressur 1g w 17-01-04

OBJ_ --------------~===:~:D:O~K~U:·31100-001.fm

( 1)

t. n! . Atten 10 . . t permissible. ·1 ble ! tl_ Dry running is no ure must be ava1 a

C-f S fficient fuel press mp. u - essure pu

at the high-pr - at least 4.3 bar Fuel pressu re at the supply

. h ressure pump. • Install hig -p t be visible.

Markings mus atch. · must m

Help marking heel

ump gear w . hi h-pressure P gear wheel (1) Marking _9 . h-pressure pump Help marking_ h1g ear

(2) and intermediate g

• Sere

Attention! - h-pressure pump. t twist the h1g Do no

won nuts (1 ).

• Tighten nuts ( 1 ).

~-,. , :, 21 Nm

• Install locking screw.

09 ____ " Module

• Install fuel pipes. 1· e . ressure in . • Fit new h1gh-p 21

.· Module .. - . , lu

. d lock cable P g. • Plug in an

0

516

II

II

High~pressure pump W 17-01-04 OBJ_DOKU-31100-001.fm

Technical Data


ID no. Name

A17 004 High-pressure pump gear wheel and high-pressure pump drive shaft

A17 031 High-pressure pump on crankcase

A. DEUTZ

Screw type Not~s / Remark Value Hold high-pressure pump

80 Nm oear wheeL

21 Nm

For the lightening procedure according lo torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

1l 0912012 6/6

Removing and installing the injector

rn Standard tools

Special tools: - Diagnostic tool

SerDia 2010 - Assembly pliers - T orx tool set - Plugs/caps - Lever tool - Disassembly tool - Extraction tool - Slide hammer

Remove injector

1 Injector

2 Sealing disc

3 Clamping claw

4 Screw

© 09/2012

01899050 01899092 01899144 02992117 02992127 02992138 02992294

1/6

Injector W 19-01-01



Danger! Do not carry out work on the fuel system when the engine is running. The fuel system is under high pressure -Danger of death.

The fuel pressure can continuously remain up to several 100 bar even after stopping the engine. Here the fuel pressure is only reduced if the fuel system is opened and the fuel can escape outside.

Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt particles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling . Collect leaking operating substances in suitable vessels and dispose of according to regulations.

II

II

Injector W 19-01-01 OBJ_DOKU-31101-001.frn

1600 bar Injection system

Attention! Note assignment of the injector to the cylinder. The injector is assigned by the relevant IMA code (1) to the corresponding cylinder. The assignment is saved in the control unit. Each time an injector is replaced/renewed, the correct assignment to the relevant cylinder must be made by transferring the new I MA code in the control unit. Observe installed injection system1 The I MA codes of the different injection systems are basically different. The injector calibration depends on the installed injection system. The exact procedure can be taken from the listed documentation and must be observed.

'--.i DiagnoStic SerOia 2010 tool

SerDia manual

The following work procedure describes the removal and installation of an injector.

Proceed in the same way lo remove further injectors.


• Disconnect the fuel line from the injector .

._.} Module 21

Attention! Position (1 ): The injector must be renewed if the pipe connection is disconnected.

• Hold pipe connection ( 1).

• Remove injection line.

/__::__.1 Module 21


© 0912012

A. DEUTZ

<'l 51243-0

2/6

A. DEUTZ

• Insert lever tool ( 1) in the clamping claw.

• Loosen the injector by moving the lever tool ( 1) in the direction of the arrow.

• Remove injector and clamping claw.

Attention! Do not brush off the nozzle tip of the iniector_

Do nol damage nozzle head on the inJector during disassembly of the sealing disc (1).

• Grip fixed sealing disc (1) using the assembly pliers (2) and pull off with slight turning movements.

Removing fixed sealing disc at cylinder head

• Insert extraction device (1) .

bl The supports (arrow} must rest in the bore EJ of the sealing disc.

3/6

Injector W 19-01-01


;) 50<62-0 II

II

Injector W 19-01-01 OBJ_DOKU-31101-001 fm

• Screw in spindle (1) until the sealing disc is fastened on the pull-out device. [~ I Hold puller on hexagon.

• Install adapter (2) on disassembly device.

• Install slide hammer ( 1) on disassembly device.

• Pull out fixed sealing disc.

Installing the injector

• Mount new sealing disc ( 1) on injector.

© 0912012

Attention! Before installing the injector, combustion residue must be cleaned carefully from the bore on the cylinder head. Suck off dirt particles.

4/6

A. DEUTZ

0

A. DEUTZ

Attention! Note assignment of the injector to the cylinder. Ensure that the installation location is free from faults.

• Insert injector carefully in the cylinder head.

• Mount clamping shoe.

• Insert screw (1) .

[:;;l Do not tighten the screw until after EJ assembling the injection line.

• Mount new injection pipe.

'--.I Module 21

Do not tighten union nuts.

Attention! Position ( 1 ): The injector must be renewed if the pipe connection is disconnected.

• Tighten screw (2) .

,'!,·-,~--,. 30 Nm

• Tighten union nuts of the inJection line.

L:,.J Module 21

• Connect fuel line.

Attention! Removed, missing and bent clips must be renewed. The clip must spring back to the hold position automatically. Otherwise renew the clip.

L., .• J Module 21

• Plug in and lock cable plug.

©0912012 5/6

Injector W 19-01-01


II

II

Injector W 19-01-01 OBJ_DOKU-31101-001,fm

Technical Data


ID no. Name

A 19 001 Injector on cylinder head, clamping claw

Screw tvoe

A. DEUTZ

Notes / Remark Value Observe order of installation. 30 Nm Install injector without tension.

For the lightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

6/6

A. DEUTZ

Fuel pre-filter

[I] Standard tools

1 Fuel pre-filter

2 Console

3 Sensor 1.6 Nm

4 Sealing ring

Use a new sealing ring.

Vent fuel system according to operating instructions.

Fuel pre-filter

[~,} Operation manual

3 09/2012 1/2

Fuel filter W 20-90-16



- Operation manual

Danger!

Do not carry out work on the fuel system when the engine is running. The fuel system is under high pressure -Danger of death.


Attention! Ensure utmost cleanliness for all work. Remove any paint residue and din particles before disassembly. Clean the area around the components concerned carefully. Blow wet pans dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

© 50549-0

II

II

Fuel filter W 20-90-16 OBJ_OO KU-31102-001 .fm

©09f/()1';

A. DEUTZ

212

A. DEUTZ

Fuel filter rn Standard tools

2

3

4

5

Fuel spare filter

Filter head

Pressure sensor

Hexagon head screw

0-ring

25 Nm

42 Nm

[ ll@f I Use new round sea ling ring.

© 0912012 1/2

Fuel filter W 20-90-17



- Operation manual



Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt particles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

© ,~551-0

II

II

Fuel filter W 20-90-17 OBJ DOKU-31103-001.fm

©09120·.2

A. DEUTZ

212

A. DEUTZ

Fuel line

2

3

4

5

Standard tools

Special tools: - Hose clip pliers - Spring band pliers - Plugs/caps

Hose pipe

Hollow screw

Sealing ring

Clip

Holding tape

20 Nm

1~ I Use new sealing rings.

©0912012

01899037 01899112 01899144

112

Fuel pipes W 20-90-30


- Safety information I User information

- Operation manual




© 50548-0

II

II

Fuel pipes W 20-90-30 0BJ_DOKU-31104-001 .fm

Attention! Ensure that the installation location is free from faults. Lay the hose pipe free from chafing and tension.

- Dimension X

© 0912012 212

A. DEUTZ

A. DEUTZ

Supply pump (Fuel)

[I] Standard tools

Special tools: - Plugs/caps

Supply pump

- Fastening

Screws

4 X M5-8.8

01899144

112

Fuel supply pump W 20-90-47



Danger!

Do not carry out work on the fuel system when the engine is running. The fuel system is under high pressure -Danger of death.



• i l • 1 I I l .,,,

. I I -=-" ti

© 5D547-D

II

II

Fuel supply pump W 20-90-47 OBJ_DOKU-31105-001 .fm

2/2

A. DEUTZ

Removing and installing the rail

[I] Standard tools: - Wrench insert size 14

Special tools: - Long socket wrench insert 01899132 - Plugs/caps 01899144 - Special wrench 02992112 - Disassembly tool 02992127

- Assembly grease 01016496

Removing the rail

1 Rail

2 High-pressure line

3 Injection line

4 Injection line

5 Torx screw

6 Spacer

© 0912012 1/10


OBJ_DO KU-31106-001 .fm




Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt particles before disassembly. Clean the area around the components concerned carefully_ Blow wet parts dry with compressed air. Observe the safety regulations and national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

4

© 50552-0

II

II

Fuel pipes W 21-04-01 OBJ_DOKU-31106-001.fm

Removing high-pressure line

• Remove fuel return line.

• Unscrew union nut ( 1) with special wrench.

• Remove cable harness holder and swing aside.

• Unscrew union nuts (2) with special wrench.

• Remove high-pressure line (3).

~ Collect draining fuel and dispose of L'.::J according to regulations.

Removing injection pipes

• Unscrew lock nuts ( 1) with special wrench.

~ Attention! lJ2J Position (3):

The injector must be renewed if the pipe connection is disconnected.

• Hold pipe connection of injector.

• Unscrew lock nuts (2).

• Remove injection lines.

rd Collect draining fuel and dispose of L'.::J according to regulations.

• Unlock cable plug .

• Pull out cable plug.


• Remove the rail (2).

• Remove spacer (3).


© 0912012

A. DEUTZ

if: 51411-0

2/10

A. DEUTZ

Removing the pressure sensor

• Unscrew the rail pressure sensor (1) with the socket wrench.

r:::;;:i Collect draining fuel and dispose of EJ according to regulations.

Attention! Do not touch the pin contacts of the rail pressure sensor with your hands to avoid electrostatic discharging. Ensure absolute cleanliness of the connector.

• Visually check the thread and the sealing edge (arrows)of the rail pressure sensor.

Installing the pressure sensor

Attention! No foreign bodies may get into the rail. Ensure utmost cleanliness. Especially on the thread and the sealing surface of the rail. See the spare parts documentation_ Rail pressure sensor and pressure limiting valve must be replaced as a pair.

• Clean thread and sealing area of the rail.

• Coat the thread and sealing edge of the rail pressure sensor lightly with assembly grease.

©0912012 3/10



©51412·0

© •30H-0

© <3017-0

II

II

Fuel pipes W 21-04-01 OBJ_DOKU-31106-001 .fm

liW Attention! LJ2J Only tighten the rail pressure sensor with

the hexagon.

• Screw in rail pressure sensor ( 1 ).

• Tighten rail pressure sensor (1) with the socket wrench insert.

§':>,~-: 70 Nm

Removing the pressure limiting valve

• Unscrew pressure limiting valve (1).

~ Collect draining fuel and dispose of EJ according to regulations.

• Visually check the thread and the sealing edge of the pressure limiting valve.

© 0912012 4110

A. DEUTZ

© 51412-0

© 51413-0

:!'.l 43253•1

A. DEUTZ

• Remove the O-ring with the disassembly tool .

Installing the pressure limiting valve

Attention! No foreign bodies may get into the rail. Ensure utmost cleanliness. Especially on the thread and the sealing surface of the rail. See the spare parts documentation. Rail pressure sensor and pressure limiting valve must be replaced as a pair.

• Mount new O-ring (1 ).

• Lightly coal the thread and sealing edge of the pressure limiting valve with assembly grease.

© 0912012 5/10



©43335-0 II

II


• Clean thread and sealing area of the rail.

• Screw in pressure limiting valve (1 ).

• Tighten pressure limiting valve.

f!;> '~::i 1 00 Nm

Mounting rail

• Mount rail ( 1) with spacer (2).

• Loosely preassemble rail (1) with screws (3). 1~1 Do not lighten screws.

Installing injection pipes

Attention! The injection lines must always be renewed after disassembly.

Note assignment and installation position of the injection lines.

• Mount new injection lines (1 ).

© 09(.10',2

A. DEUTZ

© 51413-0

© 57.dld·O

~ 01415-0

6110

A. DEUTZ

Attention! Pay attention to alignment of the injection pipes. Lines must not be in the bores (1) of the union nuts. Install injection lines without tension and without touching. They must be a safe distance away from adjacent parts.

• Align injection lines.

• Tighten union nuts hand-tight.

Installing high-pressure line

Attention! The high-pressure line must always be renewed after dismantling.

Ensure that the installation location is free from faults.

• Mount new high-pressure line (1 }.

Attention! Pay attention to alignment of the high-pressure line. Line may not touch in the bore ( 1) of the union nut. Install high-pressure line without tension and contact. They must be a safe distance away from adjacent parts.

• Align high-pressure line.

• Tighten union nuts hand-tight.

©0912012 7/10



© 51416-0 II

II



f>,, 30 Nm

• Tighten the union nuts in order.

?s, .. , 30 ~]:~ Nm

• Check injection lines for perfect installation position .

• Check the high-pressure line for perfect installation position.

• Mount fuel return line.

• Mount cable harness holder.


IIJ@f I Ensure that the connection is perfect.

8110

A. DEUTZ

A. DEUTZ

Technical Data


ID no. Name Injection line on rail and injector.

A21 003 high-pressure line on high-pressure pump and on rail

A21 038 Rail on cylinder head

A21 039 Pressure limiting valve on rail

A21 040 Pressure sensor on rail

Screw type

Union nut

M18x1.5

Notes / Remark Observe installation regulation. Use new line.

Observe assembly specification.

Lightly coat the thread and sealing edge with assembly qrease.

Lightly coat the thread and sealing edge with assembly grease.


OBJ_DOKU-31105-001.frn

Value

30 : )·~ Nm

30 Nm

100 Nm

70 Nm


© 09/2012 9110

II

II


ti 0912012

A. DEUTZ

10/10

A. DEUTZ

Removing and installing the fuel line (injector, rail, high-pressure pump)

Standard tools

Special tools: - Spring band pliers - Plugs/caps - Disassembly tool

Removing the fuel line

1 Return line

2 Hose holder

3 Fuel line

4 Hose pipe

5 Pipe clip


7 Spring band clip

© 0912012

01899112 01899144 02992127

1/6







© 50550-U

II

II

Fuel pipes W 21-05-05 OBJ_DOK U-31107-001. frn

Attention! Removed, missing and bent clips must be renewed. The clip must spring back to the hold position automatically. Otherwise renew the clip.

• Press in the clip (1) to the stop.

• Pullout return line (2).

• Remove the O-ring (1) with the disassembly tool .

• Remove return line (1) from hose holder (2).

• Unlock coupling plug (3) and pull off.


©0912012

A. DEUTZ

© 51304-0

© ,, 305-0

© 51306-0

216

A. DEUTZ

. band pliers. I. ( 1} with spring . band c ip • Loosen spring

• Pull off hose pipe (2).

return line. • Remove mponents.

. ct the co • Visually inspe

. the fuel line Mounting

· I r n is free Attention. . tallation loca ,o that the ins Ecsoce d

from faults. th the spring ban g band clip (1) w1 . the spnn • Position

pliers.

- Dimension X

• 2 mm •i~ .4-2

,, . t the hose pipe (2). • Moun

• Position res u . hose holder . t rn line. (2

) rt return line ( 1) in

• lnse . (3

)_ • Pos1t10 .. n pipe clips

• Tighten screws (4) . and latch into place. nt coupling plug (5) • Mou

:!SJ 09/2012 3/6

Fuel pipes w 21-05-05

----------()BJ_D()Kl~~31107-001.fm OBJ_DOKU-

X

©01309-0

II

II

Fuel pipes W 21-05-05 OBJ_DOKU-31107-001.lrn

Attention! Removed, missing and bent clips must be renewed. The clip must spring back to the hold position automatically. Otherwise renew the clip,

• Mount new round sealing ring (2).

• Position return line ( 1) vertically to the injector.

• Insert return line ( 1) in injector by hand.

Attention! Ensure that the installation location is free from faults. Return line must snap in audibly.


©0912012

A. DEUTZ

© 51310-0

© 51311·0

4/6

Au DEUTZ

Technical Data


ID no. Name A 12 095 Pipe clips. fastening

Screw e Notes I Remark


OBJ_0OKU-31 107-001 Jm

Value 30 Nm


5/6

II

II

Fuel pipes W 21-05-05 OBJ_DOKU-3 7 107-001 .fm

© 09.1201:;:

A. DEUTZ

6/6

A. DEUTZ

Removing and install the charge air line

[I] Standard tools

Remove charge air line

1 Charge air line

2 Seal


• Remove fuel return line.

• Unlock cable plug and disconnect.


• Remove charge air line (2).



©0912012 1/4


OBJ_OOKU-31108-001.fm

© 50•13-0

II

II

Charge air line W 22-01-01 OBJ_DOKU-31108-001.frn

Install charge air line


• Mount new gasket ( 1 ).

• Turn screws into the seal a few turns.

bl The seal is locked by the screw thread .

EJ Ensure that the installation location of the gasket is free from faults.

• Mount charge air line (1).

• Tighten screws (2). 1~ I Do not move gasket.


t'• ,, __ , 30 Nm

~ Attention! lJ2J Ensure that the cables are laid perfectly.


• Mount fuel return line.

©09/2012 2/4

A. DEUTZ

© 504 15-0

B 4 2 6

5 1 3 7

~- ~0.!117-0

A. DEUTZ

Technical Data


ID no. Name A2.2 030 Charge air line on c linder head




Value 30 Nm


3/4

II

II

Charge air line W 22-01-01 OBJ_DOKU-31108-00 t.fm

©09-12012

A. DEUTZ

4/4

• I

A. DEUTZ

Removing and installing charge air manifold

101 Standard tools: l__!L_J - Spring band pliers

Removing charge air manifold

1 Rubber sleeve

2 Hose nozzles

3 Spring band clip

4 Spring band clip

5 Spring band clip

6 Seal

7 Charge air manifold


01899112

• Loosen spring band clips ( 1) with spring band pliers.

• Unscrew screws (2) .

• Remove charge air manifold (3) .

• Remove gasket ( 4).


©09/2012 1/4


OBJ_DOKU-31109-001 .lm

·:e> 5U403-0

II

II

Charge air line W 22-04-01 OBJ_DOKU-31109-001.fm

Installing charge air manifold



• Mount charge air manifold (2).

• Fasten screws (3).

• Tighten screws alternately.

fJ,- ,_ ·:; 30 Nm

• Position spring band clips (4) with spring band pliers.

©0912012 214

A. DEUTZ

A. DEUTZ

Technical Data


ID no. Name Screw e Notes/ Remark A22 046 Char e air manifold on char e air line



Value 30 Nm

For the tightening procedure according to torque uslng a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3/4

II

II

Charge air line W 22-04-01 OBJ_OOKU-31109-001.fm

©-19120' 2

A. DEUTZ

414

A. DEUTZ


OBJ_DOKU-31110-001. Im

Pressure transmitter / temperature pressure transmitter (charge air)

1

2

3

4

5

6

7

8

Standard tools

- Fitting compound DEUTZ AP1908

Temperature sensor

Hexagon head screw

Hexagon head screw

Hexagon head screw

Pressure sensor

Console

Sealing ring

Hollow screw

9 Hose ring piece

242 Mounting compound

• Clean sealing surfaces. 1~1 Use new sealing rings.

<,) 0912012

11 Nm

30 Nm

5 Nm

18 Nm

1/2



II

II

Charge air line W 22-90-20 0BJ_DOKU-31110-001.fm

© 0912012

Positions

5

Use mounting compound.

Use new round sealing ring.

A. DEUTZ

2/2

Intake nozzle (exhaust turbocharger)

~ Standard tools: l_JL_J - Spring band pliers 01899112

1 2

3

4

5 6

7

Intake nozzle

Spring band clip

Spring band clip

Hexagon head screw 13 Nm Pipe clip

Pipe

Rubber sleeve

Push the pipe and rubber muff up as far they will go.

Position the spring band clip facing upwards in an easy to reach position.

©0912012 112

Air intake pipe W 22-90-35


II

II

Air intake pipe W 22-90-35 OBJ DOKU-31111-001 frn

A. DEUTZ

212

A. DEUTZ

Charge air manifold

[I] Standard tools

1 Charge air manifold

2 Throttle valve

3 Seal



6 Seal

1~ I Use a new gasket.

©0912012

30 Nm

13 Nm

1/2



II

II

Charge air line W 22-90-54 OBJ_DOKU~31112-001.fm

Technical Data


..

ID no. Name Screw e Notes / Remark A2.2 046 Char e air manifold on char e air line

212

A. DEUTZ

Value 30 Nm

A. DEUTZ

Charge air line

rn Standard tools

Special tools: - Spring band pliers

Rubber sleeve

2 Hose pipe

3 Spring band clip

4 Spring band clip

5 Spring band clip

6 Seal

7 Charge air line

8 Hexagon head screw g Pipe clip


11 Hose pipe

12 Hollow screw

13 Sealing ring

~ Use a new gasket.

© 0912012

01899112

13 Nm

30 Nm

30 Nm

112



II

II

Charge air line W 22-90-55 OBJ 0OKU-31113-001 .fm

©;J9/'.i;'l)12

A. DEUTZ

212

A. DEUTZ

V-rib belt pulley

[I] Standard tools

1

2

V-rib belt pulley

Hexagon head screw

©09/2012

30 Nm

1/2

coolant pump W 37-90-13


II

II

Coolant pump W 37-90-13 OBJ_DOKU-31114-001.fm

A. DEUTZ

2/2

A® DEUTZ

Drive components

[I] Standard tools

1 V-rib belt pulley


© 0912012 1/2

Coolant pump W 37-90-06


II

II

Coolant pump W 37-90-06 OBJ DOKU-31115-001 .fm

f:l 0912012

A. DEUTZ

212

A. DEUTZ

V-rib belt pulley rn Standard tools

1

2

3

V-rib belt pulley

Adapter

Hexagon head screw

© 091~01:/

30 Nm

1/2

Coolant pump W 37-90-13


II

II

Coolant pump W 37-90-13 OBJ DOKU-31116-001 .fm

~0912012

A. DEUTZ

2/2

A. DEUTZ

Removing and installing the thermostat

[I] Standard tools

Removing the thermostat

Thermostat housing

2 Thermostat

4 Sealing ring

5 Screw plug 65 Nm

6 Seal


8 Temperature sensor

• Drain, collect and dispose of coolant according to regulations

• If present: Remove coolant hose from outlet nozzle.


• Remove thermostat housing (2)


© 09120>2 1/4

Thermostat housing W 38-01-01


- Operation manual



2

7

5

© S\JBJ-0

11)51384-0

II

II

Thermostat housing W 38-01-01 OBJ_DOKU-31117-001.fm

• Remove gasket (1 ).

• Remove thermostat (2).


Installing the thermostat


• Insert thermostat (1 ).

• Insert screws ( 1 ).

• Fix new gasket (2) to the thermostat housing with screws.

Ae DEUTZ

\•'

© .51385-0

© o13A9-Q

'.Q5138b-Q

2/4

A. DEUTZ

• Mount thermostat housing (1).



• Tighten all screws ( 1 ).

:;, '<:, 30 Nm

• If present: Push coolant hose onto outlet nozzle and fasten .

• Fill cooling system according to the operating manual.

/_-.:_j Operation manual

©0912012 314

T \

l

\_ 0 '



© 51381-0

<;) 5138B-O

II

II


Technical Data


ID no. Name Screw e Notes / Remark A38 001 Thermostat housin on cylinder head

A. DEUTZ

Value 30 Nm

For the tightening procedure accordin9 to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

C09'2012 4 /4

A. DEUTZ


OBJ_DOKU-3111B-001. fm

Checking the thermostat (in the removed state)

10) Standard tools: l___LJ - Thermometer

Checking thermostat

Thermostat housing

2 Thermostat

4 Sealing ring

5 Screw plug

6 Seal


8 Temperature sensor

65 Nm

• Measure beginning of stroke, dimension (a).

• Note measured value, dimension {a).

1/4

IA) Danger! ~ Risk of injury!

Hot water and hot thermostat.

6

2

/, 4 I

5

- --a --~

7

© 513B3-0

© 51:190-0

II

II


• Heat up the thermostat in the water bath.

• Determine beginning of opening .

In order to determine the exact beginning of opening, the temperature should be measured as close as possible to the thermostat.

Do not touch the thermostat.

The waler should be continuously stirred for an even temperature distribution. The temperature rise should not take place faster than 1 °C/min. Otherwise the beginning of opening will be delayed accordingly.

- Nominal value:

,:':< 86 "C

• Measure water temperature.

- Nominal value:

:)".- 99 °C

• Measure end of stroke, dimension (b).

• Note measured value, dimension (b).

• Determine stroke.

Calculation example Desired:

Given: Measured:

Calculation:

Result:

Stroke

Beginning of stroke, dimension (a)

End of stroke, dimension (b) Dimension (b) - dimension (a)

= stroke

• Compare resull with setpoint value.

- Nominal value:

',,,, 9 mm

,f, \1~1201/

A. DEUTZ

©51J92·0

214

A. DEUTZ

Technical Data

Testing and setting data

ID no. Name P38 11 Thermostat, beginning of opening P38 13 Thermostat, stroke P38 14 Thermostat, stroke, test temperature

Additional Information

at 99 •c . minimum

3/4


OBJ_DOKU-311 18-001 Jm

Value 86 ·c 9mm 99 ·c

II

II

Thermostat housing W 38-01-02 OBJ DOKU-31118-001.fm

~ 09!2012

A® DEUTZ

414

A@ DEUTZ

Line

[I] Standard tools: - Spring band pliers


Pipe

2 Spring band clip

3 Elbow

4 Hose pipe


6 Support plate

7 Pipe clip


© 09120>2

01899112

01899144

f"

13 Nm

8 Nm \\

1/2

Coolant pipes W 38-90-32


3

2

8

II

II

Coolant pipes W 38-90-32 OBJ_ DOK U-31119-001 .Im

© 0912012

A. DEUTZ

2/2

A. DEUTZ

Line

rn Standard tools

1 Coolant line


'<' 0912012

14 Nm

1/2



© 50554-0

II

II

Coolant pipes W 38-90-32 OBJ_DOKU-31120-001 .fm

A. DEUTZ

212

A. DEUTZ

Line

[I] Standard tools

1 Coolant line



12 Washer

~0912012

14 Nm

14 Nm

1/2



II

II

Coolant pipes W 38-90-32 OBJ_DOKU-31121-001.fm

©09.'(Q12

A. DEUTZ

212

A. DEUTZ

Pressure fan

00 Standard tools

Pressure fan


©0912012 1 /2

Fan W 39-90-52


© 51338-0

II

Fan W 39-90-52 A.

DEUTZ OBJ DOKU-31122-001 fm

II

212

A. DEUTZ


00 Standard tools

Removing exhaust line

Exhaust line

2 Seal


• Remove turbocharger.

~·__:_ _ _; Module 43

• Remove cooler .

._j Module 41

• Unscrew all screws (1).

• Remove exhaust line (2) ,


©09/2Q1;. 1/4

Exhaust pipe W 41-01-01


II

II

Exhaust pipe W 41-01-01 OBJ_DOKU-31123-001 .fm

Installing exhaust line


• Clean sealing suriaces.


• Fasten new seal ( 1) with screws on exhaust line.


• Mount exhaust line ( 1 ). 1~ I Note installation position .

• Fasten ell screws (2) .

• Tighten the screws according to the tightening se-quence.

1~;- '. ·; 30 Nm

• Install the turbocharger . .. -- ...

Module 43 : ,' ·------...v

• Install cooler_ ~ ---~

L--JJ Module 41

'1>0912012 2/4

A. DEUTZ

© so,20-0

8 3 5

~ -'o

,--\ Cl)

6 4 2 7

© 50734-0

Au DEUTZ

Technical Data


ID no. Name

A41 001 Exhaust line on cylinder head

Screw type Notes I Remark Observe tightening sequence

Exhaust pipe W 41 -01-01

OBJ_0OKU-31 123-001.lm

Value

30 Nm

For the tightening procedure according lo torque using a torque wrench, a maximum variation of the tightening torque of+/• 10% is permissible.

3/4

II

II

Exhaust pipe W 41-01-01 OBJ DOKU-311 23-001 .frn

A. DEUTZ

4/4

A. DEUTZ


[I] Standard tools

Removing exhaust line

Exhaust line

2 Seal


• Remove turbocharger.

~-: . ./ Module 43

• Remove cooler.

:._:,-; Module 41

• Unscrew a II screws ( 1).

• Remove exhaust line (2).


;f.: 09i2012 1/4



II

II

Exhaust pipe W 41-01-01 OBJ_DOKU-31124-007.frn

Installing exhaust line




• Fasten new seal (1) with screws on exhaust line.


• Mount exhaust line (1 ). l~ I Note installation position.

• Fasten all screws (2).


:·:, ,. 30 Nm

• Install the turbocharger.

L.) Module 43

• Install cooler.

.:::.:) Module

©09:2012

41

2/4

A. DEUTZ

©50731·0

8 1 3 5

! C Ii _) 1 ;,J~ ,._J

6 4 2 7

.:; SO?J:,.o

A. DEUTZ

Technical Data


ID no. Name

A41 001 Exhaust line on cylinder head

Screw type Notes / Remark Observe Lightening sequence



Value

30Nm

For the tightening procedure according 10 torque using a torque wrench, a maximum variation of the tightening torque of+/- 10% is permissible.

3/4

II

II

Exhaust pipe W 41-01-01 OBJ_DOKU-31124-001 .fm

A. DEUTZ

4/4

A. DEUTZ

Connection

Exhaust gas recirculation W 41-90-04


(Crankcase housing, exhaust gas circulation, coolant line)

Standard tools

- Fitting compound DEUTZ AP1908

1 Hose nozzles

2 O-ring


[ll@rl Use new round sealing ring .

• Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound.

© 0912012 1/2



© 50387-0

II

II

Exhaust gas recirculation W 41-90-04 OBJ_DOKU-31125-001 .fm

© 0912012

A. DEUTZ

2/2

Compensator structure (Exhaust line)

[I] Standard tools

1 Compensator

2 Seal


Use a new gasket.

Attention! Check seal.

20 Nm

Ensure that the installation location is free from faults.

:I) 0912012

Install without tension (without torsional stresses) and do not pre-compress.

J

1/2



© 50386-G

II

II

Exhaust pipe W 41-90-21 OBJ_DOKU-31126-001.lm

•~ :JW/0',J

A. DEUTZ

212

A. DEUTZ

Line

Exhaust gas recirculation W 41-90-32


(Thermostat housing, exhaust gas circulation, coolant line)

1

2

3

4

5 6

7

8

9

Standard tools: - T orx tool set - Spring band pliers


Hose pipe

Spring band clip

Coolant line

Torx screw

Hexagon head screw

Pipe clip

Seal

Rubber sleeve

Sealing ring

10 Nm

8Nm

10 Screw plug 80 Nm

~ Use a new gasket.

L'.:::._J Use a new sealing ring .

01899092 01899112

01899144

1/2



© $0:lAS-O

II

II

Exhaust gas recirculation W 41-90-32 OBJ_DOKU-31127-001.fm

(S)091l012

A. DEUTZ

2/2

A. DEUTZ

Removing and installing the turbocharger

[1] Standard tools

Removing turbocharger

1 Exhaust turbocharger

2 Seal


• Remove intake nozzle.

C_:/ Module 22

• Remove the lubricating oil line.

• Remove lubricating oil return line.

L:J Module 16

• Remove exhaust manifold.

W Module 43

• Unscrew screw ( 1)

1/4

Exhaust gas turbocharger W 43-01-01


II

II

Exhaust gas turbocharger W 43-01-01 OBJ_DOKU-31128-001 .fm


• Remove turbocharger (2).

• Remove gasket (3) .


Installing the turbocharger


• Mount gasket (1 ).

'" Mount turbocharger (2) .


• Fasten screw (1) .

• Tighten screw (1).

'> ':·- 30 Nm


~;•,. ; 30 Nm

• Fit intake nozzle.

_:_,) Module 22

• I nstal I I ubricating oil line.

• I nstal I I ubricating oil return line.

:_._:_.. Module 16

• Install exhaust manifold .

Module 43

A. DEUTZ

2/4

A. DEUTZ

Technical Data


ID no. Name A43 020 Turbocharger on exhaust line



Screw e Notes / Remark Value 30Nm


3/4

II

II

Exhaust gas turbocharger W 43-01-01 OBJ_DOKU-31128-001.fm

© 0912012

A. DEUTZ

4/4

A. DEUTZ

Removing and installing the turbocharger

[I] Standard tools

Removing turbocharger

1 Exhaust turbocharger

2 Seal


• Remove intake nozzle.

L.,_i Module 22

• Remove the lubricating oil line.

• Remove lubricating oil return line.

[_-> Module 16


• Remove turbocharger (2) .



1 /4

._l I -..



© 5050~-u

II

II

Exhaust gas turbocharger W 43-01-01 OBJ_DOKU-31129-001 .fm

I nsta Iii ng the tu rboch arg er

• Clean sealing surtaces.


• Mount turbocharger (2) .


t'f<·,~::, 30 Nm

• Fit intake nozzle.

L:.J Module 22

• Install lubricating oil line.

• Install lubricating oil return line.

!_~_) Module 16

A. DEUTZ

2/4

A. DEUTZ

Technical Data


ID no. Name A43 020 Turbochar er on exhaust line


OBJ_DOKU-3 1129-00·1 Jm

Screw e Notes / Remark Value 30 Nm


C)09t2012 3/4

II

II


'<l 0912012

A. DEUTZ

4/4

A. DEUTZ

Exhaust manifold ( exhaust turbocharger) rn Standard tools

Exhaust manifold

2 Clip

3 N~ 10Nm

[~ I Note installation position.

©0912012 1/2



-- 3

ca, 50389-0

II

A. DEUTZ

Exhaust manifold (exhaust turbocharger)

[I] Standard tools

1 Exhaust line

2 Clip

3 Clip

4 Seal

9 Nm

9 Nm

~ Note installation position.

EJ Use a new gasket.

© 0912012 1/2



3 4 2

II

A. DEUTZ

Exhaust manifold (exhaust turbocharger) w Standard tools

1 Exhaust manifold

2 Clip

3 Nut 10 Nm

1~ I Note installation position.

©0912012 1/2



J 2

© 51481-0

II

II


@0912012

A. DEUTZ

2/2

A. DEUTZ

Removing and installing the belt tensioner (V-rib belt, level 1)

[I] Standard tools II ! ,1 - Operation manual

Removing the belt tensioner

Belt tensioner

2 Deflection pulley

3 V-rib belt

4 Cylinder head screw

• Remove V-rib belt.

.~ . .! Operation manual


• Remove belt tightener (2).


1/4

Add-on parts W 44-01-01


Ii;) 50562-1

II

II


OKU-31133-001 .1m OBJ_O

Installing the belt tensioner

• Moun t belt tensioner (1 ).

• Fasten screw (2).

• Tighten screw (2).

g.~'<:, 48 Nm e running direction. • Fit the -ri V "b belt according to th

W Operation manual

©091'./01Z 2/4

A. DEUTZ

A. DEUTZ

Technical Data


ID no. Name A44 041 Belt tightener on gear case



OBJ_DOKU-31133-001 .lm

Value 48 Nm

For the lightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of+/. 10% is permissible.

314

II

II

Add-on parts W 44-01-01 OBJ_DOKU-31133-001 .fm

A@ DEUTZ

4/4

A. DEUTZ

Removing and installing the generator (Clamping latch}

[I] Standard tools

Removing the generator

Clamping strap

2 Threaded piece


4 Washer



7 Spacing sleeve


9 Hexagonal nut

• Disconnect the battery's negative terminal.

• Remove plus cable.

• Pullout cable plug (1).

©0912012 1/4

•




- Operation manual

II

II

Generator W 44-02-01 OBJ_DOKU-31134-001 .fm

• Loosen screw (1 ).

• Hold nut (2).


• Loosen screws (4).

• Swing generator (5) in direction of arrow.

• Remove V-belt.

• Unscrew screw {1 ).

• Remove generator (2).


Installing the generator

• Mount generator ( 1 ).


• Insert screw (3).

• Screw on nut (4 ).

© 0912012

A. DEUTZ

2/4

A® DEUTZ

• Mount V-belt.

• Tighten V-belt (1) by turning the clamping screw (2).

• Check V-belt tension.

L:j Operation manual

• Hold screw (2)

• Tighten nut ( 1 ) .

,-":c· •.- ; 30 Nm


.:'':,. ,_--. 42 Nm


t'>,_. , 30 Nm

• Plug in the cable plug ( 1 ).

• Fit plus cable ,

• Connect !he battery's negative termina I.

3/4



II

II

Generator W 44-02-01 OBJ_DOKU-31134-001 .fm

Technical Data


ID no. Name A44 012 Generator on console A44 015 Generator at clamping latch A44 017 Clamping latch on gear case

A. DEUTZ

Screw tvoe Notes / Remark Value 42 Nm 30 Nm 30 Nm

For the lightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

414

A. DEUTZ

Removing and installing the generator (Fastening parts)

[I] Standard tools

Removing the generator



• Remove V-rib belt

L_:,,.J Operation manual



• Unlock cable plug ( 1) and disconnect.

© 09/201;! 1/4



© 50660-U

II

II

Generator W 44-02-01 OBJ_DOKU-31135-001 fm


• Remove generator (2).

• Visually inspect the components·.

Installing the generator

• Mount generator (1) .


t, ,.- . 42 Nm

• Mount cable plug ( 1) and lock.

• Fit plus cable.

• Connect the battery's negative terminal .

• Position V-rib belt.

:__:,j Operation manual

G 0912012

A. DEUTZ

2/4

A. DEUTZ

Technical Data


ID no. Name A44 012 Generator on console



OBJ_DOKU·31135-001.fm

Value 42 Nm


3/4

II

II

Generator W 44-02-01 OBJ_DOKU-31135-001. fm

G 0912012

A. DEUTZ

4/4

A® DEUTZ

Removing and installing the console (V-rib belt, level 1)

Standard tools


Removing the console

Console

2 Clamping pin


4 Clamping sleeve



• Remove V-rib belt.

/~_/ Operation manual

• Remove generator (level 1 ).

/~_j Module 44


• Remove console (2).


-t) 0912012

[ml -Operation manual

114


OBJ_DOK U-31136-001.fm

II

II

Add-on parts W 44-02-06 OBJ_DOKU-31136-001 .fm

Mounting the console


~ Make sure the clamping pin (arrow) is in EJ place .


• Apply sealing compound ( 1) evenly on the sealing surface. 1~ l Sealing cord strength approx. 3 mm

• Mount console ( 1) over the clamping pins.


M8x85-10.9


M8x60-10.9

@09/2012 2/4

A. DEUTZ

'b": 50657•iJ

A® DEUTZ

• Tighten all screws according to the tightening sequence.

f.t0 •~:) 30 Nm

• Mount generator (level 1 ).

W Module 44

• Fit the V-rib belt according to the running direction .

. 1-:...) Operation manual

© 09/2012 3/4

5

4

6



2

~ 50859•0 II

II

Add-on parts W 44-02-06 OBJ_DOKU-31136-001.fm

Technical Data


ID no. Name A44 013 Console on crankcase/ ear case

A. DEUTZ

Screw e Notes I Remark Value 30 Nm


4/4

Removing and installing the starter

[]] Standard tools

Removing the starter

1 Starter




• Unlock cable plug ( 1) and remove.

• Remove cable ties.

© 091201, 114

Starter W 44-03-01


© soJgg.o

II

Starter W 44-03-01 A.

DEUTZ OBJ_DOKU-31137-001 .fm


• Remove starter (2).


II Installing the starter

• Insert starter ( 1 ).

• Tigh1en screws (2).

'.c_;, ; 60 Nm

• Mount cable plug (1) and lock.

• Tighten cable ties_

• Fit plus cable.

• Connect the battery's negative terminal .

2/4

A. DEUTZ

Technical Data

Tightening specificatlons

ID no. Name A44 001 Starter on connection housin

Screw · e Notes / Remark

Starter W 44-03-01


Value 60 Nm


3/4

II

A. DEUTZ

Removing and installing the starter

[I] Standard tools

Removing the starter

1 Starter


• Disconnect the battery's negative terminal .




• Remove starter (2).


© 09120:2 114

Starter W 44-03-01


© 51440-0

II


DEUTZ OBJ_DOKU-31138-001 .fm

Installing the starter

• Insert starter ( 1 ).

• Insert screws (2).


tj:-,c:::, 60 Nm

~ Attention! LJ2J L_ay the cables free from chafing and ten-

sion.


• Fit plus cable.

II • Connect the battery's negative terminal.

©09/2012 2/4

A. DEUTZ

Technical Data


ID no. Name A44 001 Starter on connection housing

Screw e Notes I Remark

Starter W 44-03-01


Value 60 Nm


Is: 0912012 314

II

A. DEUTZ

Generator rn Standard tools

Generator

2 Fan

3 Spacing washer

4 Washer

5 Hexagonal nut 90 Nm 6 Voltage regulator

8 V-belt pulley

9 Ring

10 Ring

© 0912012

6 1 2

1/2

Parts to generator W 44-90-42


3 9 8 10 4 5

II

II

Parts to generator W 44-90-42 OBJ_DOKU-31139-001 Im

A. DEUTZ

212

A. DEUTZ

Generator

[I] Standard tools

1 Generator

2 Voltage regulator

3 Hexagonal nut

4 Washer

5 V-rib belt pulley

~ 0912012

90 Nm

1 /2

Parts to generator W 44-90--42


@5134B-O

II

II

Parts to generator W 44-90-42 OBJ_DOKU-31140-001 .frn

~ 0912012

A. DEUTZ

2/2

A. DEUTZ

Engine mounting rn Standard tools

1 Holder


3 Stand foot


5 Hexagonal nut

6 Washer

7 Washer

~ 0912012 112

7

' \ \,0 .,



. ~-,':,,, ~-

e~

. 6~ ,

0\

©51485-0

II

A. DEUTZ

Engine mounting

[I] Standard tools

1 Stand foot


3 Washer

© 0912012

200 Nm

1/2


OBJ DOKU-31142-001.fm

© 51481-0

II

A. DEUTZ

Engine mounting

[]] Standard tools

1 Stand foot


3 Washer

4 Mount buffer

5 Bushing

©arJJ12

200 Nm

2

112



©51<1B60

II

II

Engine mounting W 46-90-15 OBJ_0OKU-31143-001.fm

{:;-09.'2012

A. DEUTZ

212

A. DEUTZ

Impulse transmitter (camshaft) rn Standard tools

1 Impulse transmitter


• Clean sealing surfaces. 1~1 Use new round sealing ring.

Os> 09/2012

8,5 Nm

1/2

Measuring instruments W 51-90-20




II

A. DEUTZ


[I] Standard tools

Removing the connection housing

1 Connection housing


3 Bushing


CJ Module 05


• Remove connection housing (2).


© 09120\2 1/4


OBJ_DOK U-31145-001 .fm

© 50430-0

© 50431-0

II

II

Connection housing W 52-01-01 OBJ_DOKU-31145-001 tm

Installing the connection housing

• Clean contact sunaces.

b] Make sure the clamping bushings ( 1) are EJ in place.

• Position connection housing ( 1 ).

• Centre connection housing over the clamping bushings .

• Tighten screws (1 ).

• Tighten all screws ( 1) alternately.

:"'· , .. 170Nm

• Install flywheel. _ .... - !

Module 05

(i:) (J~."}(11/ 2/4

A. DEUTZ

A. DEUTZ

Technical Data


ID no. Name

A52 080 Connection housing on crankcase

Screw type Notes / Remart.



Value Tighten diagonally oppo-

170 Nm sed


© 0912012 3/4

II

II

Connection housing W 52-01-01 OBJ_DOKU-31145-001 .fm

A. DEUTZ

4/4

A. DEUTZ


[!] Standard tools



2 Hexagon head screw 8,5 Nm

3 Cover plate


5 Bushing

4


Module 05




1/4



5

II

II

Ctl·on housing Conne w 52-01-01

U-31146-00 1.fm OBJ_OOK .

ection housing Installing the conn

t surfaces. ( 1) are • Clean contac . g bushings the clampIn Make sure 1~1 in place.

• housing ( 1) · · bush-• Position connection ·ng over the clamping nection hous1 • Centre con

ings.

crews (1 ). • Tighten s ( 1) alternately. • Tighten all screws

. 170 Nm


~---... ,, _: Module 05

© 091201"2. 214

A. DEUTZ

© ~Ob72-0

A. DEUTZ

Technical Data


ID no. Name


Screwtvoe Notes / Remark



Value Tighten diagonally oppo•

170 Nm sed

For the tightening procedure according to torque using a torque wrench, a maximum .variation of the lightening torque of+/. 10% is permissible.

3/4

II

II

Connection housing W 52-01-01 OBJ_DOKU-31146-001 .fm

,e; 0912012

A. DEUTZ

414

A. DEUTZ


[I] Standard tools


Connection housing


3 Bushing


!_::_) Module 05


• Remove connection housing (2) .


<a: 09/2012 1/4



© 51359-0

©50-'31-0

II

II

Connection housing W 52-01-01 OBJ_DOKU-31147-001 rm


• Clean contac1 surfaces.

~ Make sure the clamping bushings (1) are EJ in place

• Position connection housing ( 1 )_

• Centre connection housing over the clamping bushings.

• Tighten screws ( 1)

• Tighten all screws ( 1) alternately.

,".r· •. - . 170 Nm


--~-:_) Module 05

2/4

A. DEUTZ

A. DEUTZ

Technical Data


ID no. Name


Screw type Notes / Remark




170 Nm sed

For the tightening procedure according lo torque using a torque wrench. a maximum vanal1on of the lightening torque of +/- 10% is permissible.

3/4

II

II

Connection housing W 52-01-01 OBJ_OOKU-3)147-001 Im

A. DEUTZ

4/4

A. DEUTZ

Removing and installing the connection housing rn Standard tools




3 Bushing


G Module 05



• Visually inspect the component

1/4



2 3

@51360-0

©5D4J>·0

II

II

Connection housing W 52-01-01 OBJ_DOKU-31148-D01 fm


• Clean contact surfaces.

r:::;;i Make sure the clamping bushings (1) are EJ in place.



• Tighten screws (1)

• Tighten all screws (1) alternately

,,,.,, ., 170 Nm


:_j Module 05

21<1

A. DEUTZ

A. DEUTZ

Technical Data


ID no. Name

A§2 080 Connection housing on crankcase



OBJ_OOKU-31148-001 .Im


170 Nm sed

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/. 10% is permissible

~090012 3/4

II

II

Connection housing W 52-01-01 OBJ _DO KU-31148-001 Im

A. DEUTZ

4/4

A. DEUTZ

Removing and installing the connection housing rn Standard tools


Hexagon head screw

2 Bushing


W Module 05




1/4


OBJ_OOKU-31149-001 .frn

2

© 50431-0

II

II

Connection housing W 52-01-01 OBJ_DOKU-31149-001.fm


• Clean contact surfaces

r::;:;;;i Make sure the clamping bushings ( 1) are

~ inplace



• Tighten screws (1 ).

• Tighten all screws (1) alternately.

170 Nm


_-::J Module 05

2/'1

A. DEUTZ

A. DEUTZ

Technical Data


ID no. Name


Screw type Notes / Remar1c:




170 Nm sed


!: 0912012 314

II

II

Connection housing W 52-01-01 OBJ_DOKU-31149-001 fm

~ 0912012

A. DEUTZ

4/4

A@ DEUTZ

Connection housing rn Standard tools

Connection housing

2 Hexagon head screw 8.5 Nm

3 Cover plate

4 Screw plug 80 Nm

5 Sealing ring

[u:EI Use a new sealing ring .

©0912012 112


OBJ DOKU-31150 001.fm

2 3

© 51356-0

II

A. DEUTZ

Removing and installing the glow plugs

Standard tools: - Crowfoot wrench size 10

Special tools: - Torque handle - Insert holder long

Removing the glow plugs

1 Glow plug

2 Connecting rail

3 Locking nut

• Disconnect the battery.

• Unscrew nuts (1 ).

• Remove connecting rail (2)

IE) 0912012

01899184 01899185

1/4

Start aid W 63-02-01



©51400·0

II

II

Start aid W 63-02-01 OBJ_DOKU-31151-001.tm

• Unscrew glow plugs ( 1 ).


Installing the glow plugs

• Screw in glow plugs ( 1 ).

\iB Attention! L'...£J Ensure that the installation location is free

from faults.

• Tighten glow plugs (1)

,"!, '.:.:, 13.5 Nm

• Mount connecting rail ( 1)

• Turn on new nuts (2).

\iB Attention! L'...£J Ensure that the connection 1s periect.

• Tighten nuts (2) .

.. ,,., .. 2.25 Nm

A. DEUTZ

214

Ae DEUTZ

Technical Data


ID no. Name A63 032 Glow plug on cylinder head

A63 033 Connecting rail on glow plug


Use new lock nut

Start aid W 63-02-01


Value 13.5 Nm

2.25 Nm

For the tightening procedure according 10 torque using a torque wrench, a maximum variation of the lightening torque of +/- 10% 1s permissible.

3/4

II

Start aid W 63-02-01 A®

DEUTZ OBJ DOKU-31151-001.tm

II

~ 09/2012 41'1

II

Exhaust gas treatment W 71-90-51 OBJ_DOKU-31152-001 Im

A. DEUTZ

212

A® DEUTZ

Removing and installing hydraulic pump drive

Standard tools

- Packing compound DEUTZ DW 73

Removing hydraulic pump drive







• Remove hydraulic pump drive (3).

1 /4

4

Hydraulic pump drive W 83-02-01


24-4 I_

' ~..---© ~os2,-u

II

II

Hydraulic pump drive W 83-02-01 OBJ _DOKU-31153-001.fm

Installing hydraulic pump drive

• Apply sealing compound (1} evenly on the sealing surface.

~ Sealing cord strength approx 0.5 -

~ 0.6mm.

• Mount hydraulic pump drive ( 1 ),



• Tighten all screws according to the tightening sequence

P:, 30 Nrn

~ :J9.12Cl2 2/4

A. DEUTZ

2

3

(~) :1113S-O

A. DEUTZ

Technical Data


ID no. Name

A83 003 Hydraulic purnp on crankcase/gear case

Screw type Notes"/ Remark

Hydraulic pump drive W 83-02-01


Value

30Nm

For the tightening procedure according to torque using a torque wrench, a maximum variation of the lightening torque of+/- 10% is permissible.

3/4

II

II

Special tools W 49-01-01 OBJ_OOKU-31154-001 . fm

Orders

1!:10912012

Special tools::

These must be ordered like a normal DEUTZ spare part by specifying the order number.

2/10

A. DEUTZ

01899031 Pressure pump

Checking cooling system for leak-tightness

01899037 Hose clip pliers

Loosen hose clips and fasten

01899050 Assembly pliers

Removing valve shaft seals

3110


OBJ_DOKU-31154-001 frn

© 35409-2

© 39426-'

© •9353-Q

II

II

Special tools W 49-01-01 OBJ DOKU-31154-001 fm

01899062 V-belt tension measuring device

150 to 600 N Check V-belt tension

01899092 T orx tool set

Contents of case: - Double-ended ring spanner E6/E8 - Double-ended ring spanner E 10/E 12 Socket wrench insert EB and E10 (1/4 inch) - Socket wrench insert E10 and E12 (3/8 inch) - Socket wrench insert E 18 ( 1 /2 inch)

01899093 Rotation angle disc

with magnet Setting valve clearance

A. DEUTZ

© 35•16-3

© 39432-1

~ 49342-0

4/10

A. DEUTZ

01899103 Pricker

Removing rotary shaft lip seal

01899110 Assembly lever

e. g. removing and installing valves

01899112 Spring band pliers

320 mm Tighten spring clamp

5/10



©37511-2

© :)M20-3

II

II

Special tools W 49-01-01 OBJ_DOKU-31154-001 fm

01899132 Socket wrench insert

long Installing ancl removing pressure sensors (rail pressure, oil pressure, fuel pressure)

01899144 Stoppers/caps

1 set of differently-sized stoppers and caps Sealing openings on the fuel system

01899184 Torque handle

0.6 - 1.5 Nm

~0912012 6110

..

..

..

t ··~ ..

A. DEUTZ

.. di

lil 49357-0

ls) 43663-0

©5,.98-0

A. DEUTZ

01899185 Insert holder

Drive square 1/4" Drive hexagon 1 /4"

02992112 Special wrench

Wrench size 17,

Removing and installing high-pressure lines

02992117 Lever tool

Removing the injector

7/10


OBJ_ DOK U-31154-001.fm

© 51 489-0

© 35•36-1

© 49375 -0

II

II

Special tools W 49-01-01 OBJ_DOKU-31154-001 .frn

02992127 Disassembly tool

Removing O-ring

02992138 Puller

(in conjunction with slide hammer 02992294) Removing jammed injector sealing ring

02992214 Assembly tool

Installing crankshaft sealing ring (flywheel side)

f ) 091~012

A. DEUTZ

© •9360-0

'1; 35,37. 1

. -,

8/10

A. DEUTZ

02992294 Slide hammer

(in conjunction with disassembly device 02992137) Disassembling injector sealing ring

02992301 Separating tool

Removing metal sheet lubricating oil pan from crankcase

9/10


OBJ_0OKU-31154-001.fm

© 49372-0

© 49373-0

II

II

Special tools W 49-01-01 OBJ _DOKU-31154-001 fm

:SJ 09/201 2

A. DEUTZ

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A. · 2019-07-26 · A. DEUTZ DEUTZ engines 3.1 General The documentation of the workshop manual...

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Transcript of A. · 2019-07-26 · A. DEUTZ DEUTZ engines 3.1 General The documentation of the workshop manual...