A. DEUTZ Engines Foreword DEUTZ ■

DEUTZA. 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 de velopment of the engines. Reprinting and reproductions of any kind, even in part, require our written permission 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 & Ser vice 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]

1 Foreword

114 DBJ_DOKU-310,6-001 l,n Foreword DEUTZ engines DEUTZA. ■

2/4 OBJ_DOKU-31016-001 Im DEUTZA© DEUTZ engines Foreword

• Read and observe the information in this docu • Repair of the engine must correspond to its use mentation . You will avoid accidents, retain the for the intended purpose. Only parts released by manufacturer's warranty and possess a fully the manufacturer for the respective purpose may be used for conversion work. Unauthorised mod a functional and ready to operate engine. • This engine is built exclusively for purpose ac ifications to the engine exclude manufacturer lia cording to the scope of delivery - defined by the bility for resulting damages. Failure to observe equipment manufacturer (use for the intended this will void the warranty! purpose). Any use above and beyond this is con • The engines made by DEUTZ are developed for sidered improper use. The manufacturer will not a wide range of applications. A wide range of var be liable for damages resulting from this. The iants ensures that the respective special require user bears the sole risk. ments are met. • Use for the intended purpose also includes ob • The engine is equipped according to the installa servance of the operating, maintena nee and re tion case, i.e. not all the parts and components pair instructions specified by the manufacturer. described in this documentation are installed in The engine may only be used, maintained and your engine necessarily. repaired by persons who are familiar with this • We have done our best to highlight the differenc and are aware of the risks involved. es so that you can easily find the operating, main • Make sure that this documentation is available to tenance and repair instructions relevant to your everyone involved in the operation, maintenance engine. and repair and that they have understood the contents. • Failure to observe this documentation may lead to malfunctions and engine damage as well as in jury to persons for which the manufacturer will not accept any liability. • Prerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and special tools and the ir perfect condition. • Engine parts such as springs, clamps. elastic re taining rings etc. pose an increased risk of injury when handled incorrectly. • The pertinent rules for the prevention of acci dents and other generally recognised health and We are at your service for any questions you may safety regulations must be observed. have in this matter. • Maximum economy, reliability and long life is only guaranteed when using DEUTZ original parts. Your DEUTZ AG

2 General

©U91,01, 2/4 OBJ DOKU-31017-001 Im DEUTZA. DEUTZ engines General

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 II high environmental protection requirements are also met.

Maintenance and care are the only way the engine can satisfy the demands you make on it. Compli ance 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 particular ly 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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3 Safety information I User information

00912012 1/8 Safety information I User information OEUTZ engines DEUTZA. OBJ_DOKU-31078-001.fm

3.1 General 3.2 Specifications The documentation of the workshop manual has 3.2.1 Accident prevention and safety regula- been created based on the engine available at the tions time of going to press. The legally prescribed rules for the prevention of ac There may be deviations in the descriptions, illustra cidents must be observed_These are available from tions and parts due to further developments. professional associations or from dealers_These The valid documentations published by DE UTZ AG are dependent on the application site, operating (for example Technical Circulars, Service Bulletins, mode and the operating and auxiliary materials be II etc.) must be observed. ing used. The maintenance work described in the operation Special protection measures are specified depend manual and in the workshop manual must be carried ing on the work being carried out, and are identified out on schedule and completely. The maintenance in the JOb description. personnel must have the necessary technical Among other things it generally applies that: knowledge to pertorm the work. Safety and protec tion devices which are removed during maintenance • for the personnel: work must be replaced again afterwards. - Only briefed personnel may operate or main Caution! tain the engine. Unauthorised persons are prohibited access to the machine room. The rules for the prevention of accidents and the safety regulations must be observed during mainte - Wear close-fitting clothing and ear protectors nance work. in the machine room when the engine is in op eration. Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must - Only deploy trained personnel to do repairs be read before working on the engine and must be and maintenance work. strictly followed. - Do not work on the fuel system when the en The maintenance intervals and the work to be per gine is running. The fuel system is under high formed are specified in the maintenance schedule pressure - danger of death. of the operation manual. The job cards contain tech - Go to the workshop immediately in case of nical documentation on the execution of mainte leaks in the fuel system. nance work. • for the engine room: - Ensure adequate ventilation ( do not cover air shafts). - Provide first aid kit and suitable fire extinguish ers. Check the filling and readiness for opera tion regularly - Only store inflammable materials in the ma chine room if they are essential for operation of the system. - Smoking and naked flames are prohibited in the machine room. • for operation, maintenance and repairs on the engine: - The common rail systems used work with op erating pressures up to approximately 2000 bar. In the case of poten tial faults, the pressure can even rise to signif icantly 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 sys tem, the fuel pressure in the common rail sys tem will still not have dissipated after 30 seconds. The fuel pressure can permanently be several 100 bar.

The fuel pressure here does not drop until the Notes and measures to be observed before starting fuel system is opened and the fuel can es work on the fuel system cape. • The fuel system must be closed. Make a visual - Only start the engine when all the protective inspection for leaks I damage to the fuel system. devices have been fitted. Make sure no-one is • Clean the whole engine and engine room with the standing in the danger area. system closed before starting work on the fuel - Cleaning, maintenance and repair work may system. only be performed with the engine at a stand • The engine must be dry when you start working II still and secured against starting. on the fuel system. - Fuel lines, injection lines or fuel high-pressure • Blowing (dry) with compressed air is only permis lines must never be disconnected when the sible with the fuel system closed. engine is running. • When using a steam jet, first cover up the control - Danger of injury ! unit. the cable plugs, all other electrical plug con The fuel jet can deeply penetrate the skin. nections and the generator. Also, the steam jet - Do not come close to the leakage area in the may not be pointed directly at them. fuel high-pressure system with any body parts • Electrical plug connections must be plugged (for example hand). when spraying. - Always carry out an exact visual inspection of • Remove loose parts (for example paint chips all high-pressure carrying components before from assembly work) with an industrial vacuum tests on the running engine. Wear suitable cleaner or other suction device. Only suction may protective clothing (for example goggles, be used in assembly work on the open fuel sys gloves) for this. Leakages entail potential haz tem. ard sources for the workshop personnel. • Only work on the fuel system in a clean environ - Even if no leakages can be discerned in the ment (no dust. no grinding or welding). Avoid fuel high-pressure system, the workshop per draughts (dust). Clean the workshop floor regu sonnel should avoid the direct hazard zone or larly. No brake or performance test benches may wear protective clothing (for example goggles, be kept or operated in the same room. gloves) during tests when the engine is run ning and during the first test run. • Air currents which kick up dust, such as those caused by brake repairs or the starting of en - Always stay out of range of a fuel Jet, as it gines, should be avoided. could cause severe injury. • For work such as removal and installation on de - Fuel lines. injection lines and high-pressure fective hydraulic components on the Common lines must not be deformed. Rail System it is recommended to partition off a - Damaged fuel lines. injection lines and high separate workshop area in the factory. This must pressure lines must be replaced. be separate from other areas in which general - Smoking is strictly prohibited when working on vehicle repairs such as brake repairs are carried the fuel system. out. - Do not work near to sparks and flames. • No general machine tools may be operated in - Never disconnect an injector when the engine this room. is running. • Regular cleaning of the workshop area is manda - Loosen screw connections slowly and not tory. Draughts, ventilation systems and heating abruptly fans should be minimised. - Open screw connections on the fuel system • Areas of the engine room from which particles of with extreme caution. dirt could be loosened (for example the bottom part of the lipped driver cab) must be covered - After all work on the fuel system, it must be with fresh clean film. bleeded - see the operation manual, chapter "6 Fuel system". • Working materials and tools must be cleaned be fore work. Only use tools without damage to 1he 3.2.2 Cleanliness instructions and measures chrome plating or tools which are not chrome for working with common rail systems plated. The common rail systems used in DEUTZ engines Notes and measures to be observed during work on comprise high-precision components subjected to the fuel system or with the fuel system open. extreme loads. In view of the high-precision technol ogy, ensure utmost cleanliness when working on • Only work in clean overalls. the fuel system.

• Only lint-free cleaning cloths may be used for Noles and measures for workbench and tools in the work on the fuel system. vehicle hall • Remove loose parts (for example paint chips • A special workbench must be set up for work on from assembly work) with an industrial vacuum removed components. cleaner or other suction device. Only suction may • Clean the removal and installation tools regularly be used in assembly work on the open fuel sys and keep them in a closed tool cabinet. tem. • Remove loose parts (for example paint chips • Working materials and tools must be cleaned be from assembly work) with an industrial vacuum fore work. Only use tools without damage to the II cleaner or other suction device. chrome plating or tools which are not chrome plated. • Working materials and tools must be cleaned be fore work. Only use tools wi1hout damage to the • Do not use used cleaning fluid or test fluid for chrome plating or tools which are not chrome cleaning. plated. • Compressed air must not be used for cleaning on the open fuel system. 3.2.3 Additional information and measures for the handling of exhaust aftertreatment • Work on removed components may only be per systems formed at a suitably equipped workbench. • When removing and installing components. no • Basically all the same regulations and instruc materials which can leave behind particles or fi tions up to and including chapter 3.2.2 must also bres (cardboard, wood, cloths) may be used. be observed for work on exhaust aftertreatment systems! • Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be • Utmost cleanliness must be observed for all rubbed into the components. work. • Openings on the components and on the engine DPF (Diesel Particle Filter) must be closed immediately with suitable stop • The filter regeneration must be deactivated or, in pers/caps. systems with a filter regeneration prompt, not ac • The stoppers/caps may only be removed imme tivated before performing service work. diately before installing. • The duration of a full filler regeneration is 25 min • Store stoppers/caps free from dust and dirt in the utes on average. High exhaust temperatures oc original packaging and dispose of after using cur in the exhaust system/on lhe end exhaust once. pipe independently of the actual load state of the engine (i.e. also during engine idling). • Only remove new parts from the original packag ing Just before installation. • No foreign bodies may get into the exhaust line or the combustion chamber. If this happens, the en • Removed components must be kept in new, seal gine must be "run free" without able bags or - if available - in the packaging of the diesel particle filter. new parts. • Tensions and deformations of the shape of the V • Always use the original packaging of the new part belt clip must be avoided. The DPF module may to send back the removed components. only be transported using the transport sleeves. Notes and measures for the vehicle workshop area • V-belt clips and seals may not be reused (this • For work such as removal and installation on de also applies as soon as the screw connection has fective hydraulic components on the Common been loosened once). Rail System it is recommended to partition off a Ignition system separate workshop area in the factory. This must • Caution! Dangerous high voltage. be separate from other areas in which general The ignition system operates with ignition voltag vehicle repairs such as brake repairs are carried es up to 10000 Volts. out. • The ignition system must not be operated without • The workshop floor is sealed or tiled. a secondary load. • No welding gear, grinders, general machine • Store the components in a dry and clean area. tools, brakes or performance test benches may be operated in this room. • It is not permitted to store the components tem porarily or stack them without their transport • Regular cleaning of the workshop area is manda packaging. tory. Draughts, ventilation systems and heating fans should be minimised. • Components may only be stored and transported in the specified packaging.

{) Q91;t()12 5/8 Safety information/ User information DEUTZ engines DEUTZA. OBJ_OOKU-31078-001.fm

• Only remove new parts from the original packag Disposal includes recycling and the scrapping of ing just before installation. parts/ operating materials, although recycling has • Incorrectly operated or damaged components or priority. parts that have been dropped must not be in Details of disposal and their monitoring are gov stalled. erned by regional, national and international laws • Do not subject the components to any hard im and directives which the system operator must ob pacts or any other use of force. serve on his own responsibility. II • 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 con tact with electronic components or similar. • Leaks on the Ad Blue® pipes, the tank, the supply module and the feeding unit must be fixed imme diately to avoid leakage of AdBlue®. • Make sure the room is well ventilated. • Contact with the skin should be avoided. Wear la tex 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 re newed parts/ operating materials must be stored, transported and disposed of according to regula tions. The owner himself is responsible for this.

3.3 Operation manual and workshop man- 3.4 Job cards ual The job cards are differentiated into "W" and "I" job In order to structure the information layout in a user cards. friendly way, the service documentation is divided The "W' job card documents the standard repairs to into operating instructions and Job cards (workshop the engine and/or its components. The necessary manual). tools and special tools are also indicated in the "W" The operation manual contains a general descrip job card. The "I" job card also documents corresponding tion and instructions for all other maintenance work_ II workflows for repairing the engine and/or its compo II contains the following chapters: nents. Special prerequisites must be fulfilled by the 1. Contents, General workshops for implementation of these workflows. 2. Engine description For example, special tools and machine tools must be available. 3. Operation 4. Operating media 3.4.1 Numbering of job cards 5. Maintenance The job card numbering uses the format W 08-03- 01. The individual parts of this formal are explained 6. Care and maintenance work below: 7. Faults, causes and remedies • W 08-03-01: Documentation type 8. Engine conservation - W .... Workshop manual 9. Technical data - I ...... Repair manual 10.Service • W 08-03-01: Module The use of job cards (workshop manual) presuppos es knowledge of the operating instructions content, according to module list this applying in particular for the service specifica • W 08-03·01: Component group tions. Repairs to the engine and components are • W 08-03-01: Consecutive number described in the job cards (workshop manual), for the implementation of which more effort and corre spondingly qualified experts are required.

3.4.2 Structure of a job card 3.5 Explanation of symbols

Danger! of death or to health. Must be observed! For example: The incorrect use or conver sion of the turbocharger can lead to serious injury. Caution! II Danger to the componenVengine. Non compliance can lead to destruction of the componenUengine. Must be observed!

15 Note General notes on assembly, environmental protection etc. No potential danger for man or machine. Tool Conventional and special tools required for _ ___. 9 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 1. DEUTZ AG, publisher of service documentation Reference 2. Number of associated spare parts list sheet within the workf1ow or to assemblies in (ETL) which further documents or job cards are 3. Assembly - Designation provided. 4. Numbering of the job cards Test and setting data 5. DEUTZ internal creation number The necessary values are indicated here with link to a table within the job card. 6. Title of job card Tightening specifications 7. References/ Notes The necessary values are indicated here 8. Chapter with link to a table within the job card. 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

8/8 Job card overview DEUTZA. Sorted alphabetically OBJ_DOKU-31079-001.lm

II 5 Job card overview

5.1 Sorted alphabetically

1/12 Job card overview Sorted alphabetically DEUTZA. OBJ_DOKU-31079-001.fm

Activity Job card Module

Charge air line W 22-90-55 Charge air line

Charge air manifold W 22-90-54 Charge air line

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

Closing parts W 02-90-01 Lubricating oil sump

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

Connection (Crankcase housing, exhaust gas circu- W 41-90-04 Exhaust gas recirculation lation, coolant line) Connection housing W 52-90-53 Connection housing II Console W 71-90-51 Exhaust gas treatment

Drive components W 37-90-06 Coolant pump

Engine mounting W 46-90-15 Engine mounting

Engine mounting W46-90-15 Engine mounting

Engine mounting W 46-90-15 Engine mounting

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

fuel filter W 20-90-17 fuel filter

Fuel line W 20-90-30 Fuel pipes

Fuel pre-filter W 20-90-16 Fuel filter

Generator W 44-90-42 Parts to generator

Holder W 09-90-09 Gearcase

Impulse transmitter (camshaft) W 51-90-20 Measuring instruments

Intake nozzle (exhaust turbocharger} W 22-90-35 Air intake pipe

Intermediate gear W 09-90-50 Gearcase

Line W 38-90-32 Coolant pipes

Line W 01-90-32 Crankcase breather

Line W 38-90-32 Coolant pipes

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

Lubricant oil filter console W 15-90-38 Lubricating oil filler

Oil filling W 02-90-24 Lubricating oil sump l· Oil measuring device W 01-90-23 Oil measuring device

Pressure fan W 39-90-52 Fan

Activity Job card Module Pressure transmitter I temperature pressure trans- W 22-90-20 Charge air line milter (charge air)

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

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

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

Removing and installing the belt tensioner (V-rib W 44-01-01 Add-on parts belt, level 1)

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

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

Removing and installing the connection housing W 52-01-01 Connection housing Removing and installing the console (V-rib belt. level W 44-02-06 Add-on parts 1)

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

Removing and installing the exhaust line W41-01-01 Exhaust pipe

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

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

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

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

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

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

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

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

Removing and installing the injector W 19-01-01 Injector

Removing and installing the lubricating oil cooler W 15-02-01 Lubricating oil cooler Removing and installing the lubricating oil line (ex- W 16-04-01 Lubricating oil pipe haust turbocharger)

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

Removing and installing the lubricating oil pan W 02-01-01 Lubricating oil sump Removing and installing the lubricating oil return line W 16-05-01 Lubricating oil pipe (exhaust turbocharger)

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

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

4/12 Job card overview DEUTZA. Sorted alphabetically OBJ_DOKU-31079-001. fm

Activity Job card Module Removing and installing the rail W 21-04-01 Fuel pipes

Removing and installing the starter W 44-03-01 Starter

Removing and installing the thermostat W 38-01-01 Thermostat housing

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

Removing and installing the turbocharger W 43-01-01 Exhaust gas turbocharger

Removing and installing the turbocharger W 43-01-01 Exhaust gas turbocharger Renewing the crankshaft sealing ring (flywheel side) W 01-02-01 Crankcase II Supply pump (Fuel) W 20-90-47 Fuel supply pump

V-rib belt pulley W 37-90-13 Coolant pump

V-rib belt pulley W37-90-13 Coolant pump

©.0912072 6/12 Job card overview DEUTZA. Sorted numerically OBJ_DOKU-31079-001. Im

5.2 Sorted numerically ■

Job card Activity Module

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

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

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

W 01-90-23 Oil measuring device Oil measuring device

W 01-90-32 Line Crankcase breather

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

W 02-90-01 Closing pans Lubricating oil sump W 02-90-24 Oil filling Lubricating oil sump II Removing and installing the flywheel (Fastening W 05-03-01 Flywheel parts)

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

W 09-90-09 Holder Gearcase

W 09-90-50 Intermediate gear Gearcase

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

W 15-90-38 Lubricant oil filter console Lubricating oil filter

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

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

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

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

W 19-01-01 Removing and installing the injector Injector

W 20-90-16 Fuel pre-filter Fuel filter

W 20-90-17 Fuel filter Fuel filter

W 20-90-30 Fuel line Fuel pipes

W 20-90-47 Supply pump (Fuel) Fuel supply pump

W 21-04-01 Removing and installing the rail Fuel pipes

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

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

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

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

W 22-90-35 Intake nozzle (exhaust turbocharger) Air intake pipe

Job card Activity Module

W 22-90-54 Charge air manifold Charge air line

W 22-90-55 Charge air line Charge air line

W 37-90-06 Drive components Coolant pump

W 37-90-13 V-rib belt pulley Coolan1 pump

W 37-90-13 V-rib belt pulley Coolant pump

W 38-01-01 Removing and installing the thermosta1 Thermostat housing

W 38-01-02 Checking the thermostat (in the removed state) Thermostat housing II W 38-00-32 Linc Coolant pipes W 38-90-32 Line Coolant pipes

W 38-90-32 Line Coolant pipes

W 39-90-52 Pressure fan Fan

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

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

W41-90-21 Compensator structure (Exhaust line) Exhaust pipe

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

W 43-01-01 Removing and installing the turbocharger Exhaust gas turbocharger

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

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

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

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

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

W 44-03-01 Removing and installing the starter Starter

W 44-90-42 Generator Parts to generator

W 46-90-15 Engine mounting Engine mounting

©:J9il.lJ1l 10/12 Job card overview DEUTZA. Sorted numerically OBJ_DOKU-31079-001 .frn

Job card Activity Module W 51-90-20 Impulse transmitter (camshaft) Measuring instruments

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

W 52-90-53 Connection housing Connection housing W 63-02-01 Removing and installing the glow plugs Start aid II W 71-90-51 Console Exhaust gas treatment

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

11 /12 Job card overview Sorted numerically DEUTZA. OBJ_DOKU-31079-001.tm

6 Job cards II

Renewing the crankshaft sealing ring (flywheel side)

Standard tools

[I] Special tools: - Pricker 01899103 - Assembly lever 01899110 - Assembly tool 02992214

- Self-tapping screw ~ - Washer II

Removing the crankshaft sealing ring

Gasket housing 2 Shaft sealing ring 3 Hexagon head screw 188 Packing compound

<::/5051d-~

• 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!

al< 7083-1

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

•Pullout the crankshaft sealing ring with assembly le ver.

~ Ensure that the crankshaft does not get I , EJ damaged. L• • Visually inspect the crankshaft sealing ring running surface. C

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 Crankcase DEUTZA. W 01-02-01 OBJ_00 KU-31 081-001 .fm

• Place the crankshaft sealing ring carefully on the pe ripheral 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). 0

• 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 ~ L •

()• •7091·1

(1) 09/2012 3/4 Crankcase W 01-02-01 DEUTZA. OBJ _OOKU-31 081-001.lm

Removing and installing the gasket housing

Standard tools: - Splint driver

- Packing compound DEUTZ OW 67

Removing the gasket housing

1 Gasket housing 2 Shaft sealing ring 3 Hexagon head screw 188 Packing compound

• Remove flywheel. 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).

• Knockout crankshaft sealing ring (1 ). It@ Attention! li2J Do not damage the sealing surfaces.

• Visually inspect the components.

II 0 50520 0

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.

!.: 50521 0

• Mount gasket housing. • Tighten screws ( 1 ).

30912012 214 Crankcase DEUTZA. W 01-03-01 OBJ_DOKU-31082-001.fm

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

• Tighten the screws according to the tightening se quence. !'!,·. 20 Nm

• Renew crankshaft sealing ring (flywheel side).

~ ---. ~ ,__ . Module 01

• Install lubricating oil pan. / ___ / Module 02

• Install connection housing. ,:_ _} Module 52 • Install flywheel.

•-I :/ Module 05

3/4 Crankcase W 01-03-01 DEUTZA. OBJ_DOKU-31082-001.Im

Technical Data Tightening specifications ID no. Name Screwtvoe Notes / Remark Value Observe tightening A01 095 Gasket housing on crank.case 20 Nm sequence

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

4/4 Crankcase A. W 01-07-05 DEUTZ OBJ_DOKU-31083-001.fm

Removing and installing the transfer line

Standard tools

- Packing compound DEUTZ OW 73

Removing the transfer line

1 Transfer line 2 Torx screw 3 Screw plug 35 Nm 291 Packing compound

• Remove lubricating oil pan. L) Module 02 • Unscrew screws ( 1). • Remove transfer line (2). • Visually inspect the component.

Installing the transfer line • Clean sealing surfaces. ~ Attention! L...i2J No packing compound must get into the oil channel (1 )!

\ .. ( ., II . e 50723-1

• Apply sealing compound (1) evenly on the sealing surface. 0

• Clean sealing surfaces. • Mount transfer line (1 ). • Tighten screws (2). -'"'· -:., 20Nm • Install lubricating oil pan . ...:....} Module 02

214 Crankcase DEUTZA. W 01-07-05 OBJ_DOkU-31083-001 fm

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A01 016 Transfer line on crankcase 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 Crankcase W 01-07-05 A. DEUTZ OBJ_DOKU-31083-001.fm

4/4 Oil measuring device DEUTZA. W 01-90-23 OBJ_DOKU-31084-001 .Im

Oil measuring device

[1J Standard tools

Oil dipstick 2 Ball 3 Stopper 4 Guide tube 5 0-ring

IIJ@rl Use new round sealing ring.

.: 50392·0

'9 0912012 2/2 Crankcase breather DEUTZA. W 01-90-32 OBJ_DOKU-31085-001.fm

Line rn Standard tools

Pipe clip 2 Pipe 3 Spring band clip 4 Rubber sleeve 5 Intake nozzle 6 Spring band clip 7 Hexagon head screw 8 Nm

Removing and installing the lubricating oil pan

Standard tools Attention! Make sure that no gasket residue falls into []] Special tools: the crankcase. - Separating tool 02992301 Seal all openings. - Packing compound Collect leaking operating substances in DEUTZ OW 73 suitable vessels and dispose of according to regulations. Emptying and filling the engine with opera ting media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer. II

Removing the lubricating oil pan 244 Lubricating oil pan 2 Nut 3 Torx screw 244 Packing compound

2 4 t,512860

• Drain lubricating oil, collect and dispose of according to regulations. • Unscrew all screws (arrow). • Remove lube oil tray (1). • • • • • , ' - ' • r l

I I • l J - • • • ·-~·11 --· 1

1/6 Lubricating oil sump W 02-01-01 A. DEUTZ 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. • Remove lubricating oil pan.

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. II 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.

;; 51292-C

• To align the lubricating oil pan, screw four pin bolts ( 1} diagonally opposed into the crankcase. I _q :ll - --- - Iij • • • --L~ I I . - . ~~C - ,

'•· ~~~-- -· . I

3/6 Lubricating oil sump W 02-01-01 DEUTZA. OBJ_DOKU-31086-001 fm

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

• Apply packing compound to the joints (arrows).

II © 51:/93-0

• Apply packing compound evenly to the sealing sur face.

• Align the lubricating oil pan in the appropriate instal lation position with the pin bolts. • Mount lubricating oil pan. Attention! Do not move the lubricating oil pan any more. r , Observe the drying time for the packing l 1 • compound. ,. • • • Unscrew the pin bolts. I

• Fasten all screws (1). •I I~ J. , •'~\ •T - • • •• •· • 0 @ 51295-0

• Tighten the screws according to the tightening se quence. !P,r~ 20 Nm • Fill in lubricating oil according to operating manual.

14 13 1 2 3 4 5 15 16

~ 0912012 5/6 Lubricating oil sump W 02-01-01 DEUTZA. OBJ_DOKU-31 086-001 .Im

Technical Data Tightening specifications ID no. Name Screwtvpe Notes / Remark Value Observe lightening A02 030 Lubricating oil pan on crankcase 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. II

Closing parts rn Standard tools Collect draining lubricating oil and dispose of properly.

1 Screw plug 55 Nm 2 Sealing ring 1~1Use a new sealing ring.

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

2/2 Flywheel DEUTZA. W 05-03-01 OBJ_DOKU-31089-001 .fm

Removing and installing the flywheel (Fastening parts)

Standard tools

[I] Special tools: - Guide pin (self-const ructed) - Auxiliary screws M10x120 - Rotation angle disc 01899093 II

Removing the flywheel

Flywheel 2 Ring gear 3 Screw 4 Bearing bush

• Hold the crankshaft at the central screw. • Screw in auxiliary screws ( 1 ). • Unscrew screws (2). • Remove flywheel using auxiliary screws. • Visually inspect the components.

~ 5M62-U

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.

Technical Data Tightening specifications

ID no. Name Screw type Notes / Remark Value Stage 1: A05 001 Flywheel on crankshaft 30 Nm Use new screws A05 001 Flywheel on crankshaft Stage 2: 60° A05 001 Flywheel on crankshaft Stage 3: 30°

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

11: 09120',2 4/4 Cylinder head cover DEUTZA. W 08-01-01 OBJ_DOKU-31090-001 fm

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 DEUTZA. OBJ_OO KU-37090-001 .fm

• Remove gasket ( 1 ).

II ~ 50509 0

Installing cylinder head cover.

• Mount new gasket (1).

G 50509-0

• Mount cylinder head cover (1).

2/4 Cylinder head cover W 08-01-01 OBJ_DOKU-31 090-001. fm

• Tighten the screws according to the tightening se quence. §,"•~ 8.5 Nm • Install crankcase breather. W Module 01

4 5

Technical Data Tightening specifications ID no. Name Screw e Notes/ Remark Value A08 004 Cylinder head cover on cylinder head 8.5Nm

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

4/4 Gearcase ~>® DEUTZ W 09-90-09 OBJ_0OKU-31091-001 fm

Holder

[1] Standard tools - Safety information / User information

Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles 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 immedia tely before assembling. II

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.

~51285-0

~ 0912012 1/2 Gearcase W 09-90-09 A. DEUTZ OBJ DOKU-31091-001 ,lm

212 Gearcase DEUTZA. W 09-90-50 OBJ _DOKU-31 092-001.fm

Intermediate gear

[I] Standard tools

1 Intermediate gear 2 Shaft 3 Hexagon head screw 30 Nm

Removing and installing the lubricating oil cooler

[]] Standard tools 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.

Removing the lubricating oil cooler . ( ( 1 Lubricating oil cooler 2 Seal 3 Hexagon head screw

• Unscrew all screws ( 1 ). • Remove lubricating oil cooler (2). • Remove gasket (3). r:;;i Collect draining lubricating oil and dispose EJ of property.

• Visually inspect the components.

~ 5C279 0

~ 09/2012 1/4 Lubricating oil cooler W 15-02-01 DEUTZA. OBJ_DOKU-31093-001.fm

Installing the lubricating oil cooler • Visually inspect the components. • Clean sealing surfaces. • Turn in screws (arrows). M8x20-10.9 • Fasten new seal (1) on lubricant oil cooler housing with screws.

II I:: 50280·0

• Mount lubricating oil cooler ( 1 ). • Tighten screws (2) • Tighten all screws (2) alternalely . .-"'" • ·. 30 Nm

~)5C2S1-0

2/4 Lubricating oil cooler DEUTZA. W 15-02-01 OBJ_DOKU-31093-001 fm

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A 15 051 Oil cooler housing on crankcase 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 Lubricating oil cooler W 15-02-01 DEUTZA. OBJ_DOK U-31 093-001.fm

:al 09120"2 4/4 Lubricating oil filter DEUTZA. W 15-90-38 OBJ_DOKU-31094-001 .fm

Lubricant oil filter console

[I) Standard tools 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 Interchangeable filter 12 Nm 2 Threaded bush 3 Cover ·1 4 0-ring "'l ;, ( 5 Hexagon head screw 30 Nm - 5 ~ ,~, Use new round sealing ring. JQ• '~~ lq• • lP' 2

:;;, 50390-0

1/2 Lubricating oil filter A. W 15-90-38 DEUTZ OBJ_DOKU-31094-001.frn

2/2 Oil suction pipe DEUTZA. W 16-01-01 O8J_DOKU-31095-001.fm

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 291 Packing compound

G) 5()409-0

• Remove lubricating oil pan. !..._:j Module 02

• Unscrew screws ( 1). • Remove oil suction pipe (2). • Visually inspect the component.

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 ). • Tighten screws (2). !'!• ,.·.:·, 22 Nm • Install lubricating oil pan.

~ 1 Module 02

I © 50727-0

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A16 015 Oil suction pipe on crankcase M8x25-10,9 22 Nm

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

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

Removing and installing the lubricating oil line ( exhaust turbocharger)

[1] Standard tools 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.

Removing the lubricating oil line

1 Lubricating oil line 2 Hollow screw 3 Sealing ring

• Unscrew hollow screw ( 1 }. • Remove sealing rings (2).

• Unscrew hollow screw ( 1 ). • Remove sealing rings (2). • Remove lubricating oil pipe (3).

Installing the lubricating oil line

• Clean sealing surfaces. • 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). • Tighten hollow screw (3). 18 Nm Attention! Install tension-free.

©:)9/2012 214 Lubricating oil pipe W 16-04-01 OBJ_DOKU-31096-001.fm

• Tighten hollow screw ( 1) . !'!'·,::: 18 Nm ltW Attention! ~ Install tension-free.

(;)0912012 314 Lubricating oil pipe W 16-04-01 DEUTZA. OBJ_DOKU-31096-001 fm

Technical Data Tightening specifications ID nQ. Name Screw tvoe Notes / Remark Value Lubricating oil pipe on exhaust tur- A43 047 Hollow screw Use new sealing rings 18 Nm bocharQer A43 048 Lubricating oil line on crankcase Hollow. screw Use new sealing rings 18 Nm

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

4/4 Lubricating oil pipe DEUTZA. W 16-04-01 OBJ_DOKU-31097-001.frn

Removing and installing the lubricating oil line (exhaust turbocharger)

[I] Standard tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. Observe the appropriate operating instruc tions for emptying and filling the engine.

Removing the lubricating oil line

1 Lubricating oil line 2 Hollow screw 3 Sealing ring

• Unscrew hollow screw (1). • Remove sealing rings (2).

G) 0912012 114 Lubricating oil pipe W 16-04-01 DEUTZA. OBJ_DOKU-31097-001,lrn

• Unscrew hollow screw (1). • Remove sealing rings (2). • Remove lubricating oil pipe (3).

Installing the lubricating oil line

• Clean sealing surfaces. • 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.

:;l 50676-C

2/4 Lubricating oil pipe DEUTZA. W 16-04-01 OBJ DOKU-31097-001.fm

• Tighten hollow screw (1 ).

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

Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Lubricating oil pipe on exhaust tur- A43 047 Hollow screw Use new sealing rings 18 Nm bocharger A43 048 Lubricating oil line on crankcase 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. II

()0912012 4/4 Lubricating oil pipe W 16-05-01 OBJ_DOKU-31098-001.fm

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

Standard tools Collect leaking operating substances in suitable vessels and dispose of according Special tools: to regulations. - Disassembly tool 02992127 Observe the appropriate operating instruc - Fitting compound tions for emptying and filling the engine. DE UTZ AP1908 II

Removing the oil return line

1 Fastening flange 2 0-ring 3 Oil return line 4 0-ring 5 Hexagon head screw 6 Hexagon head screw 7 Seal

• Unscrew screws ( 1). • Remove gasket (2).

116 Lubricating oil pipe W 16-05-01 A. DEUTZ 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. • Visually inspect the component. 0

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

216 Lubricating oil pipe DEUTZA. W 16-05-01 OBJ _DOKU-31098-001.fm

Mounting the oil return line • Clean sealing surfaces. • Lightly coat new round sealing ring with DE UTZ AP1908 mounting compound. • Insert new O-ring { 1 ).

• Clean sealing surfaces. • Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound. • Insert new O-ring (1). • Insert flange (2) in direction of arrow.

• Clean sealing surfaces. • Mount oil return pipe { 1 ). • Insert oil return line ( 1) in direction of arrow. • Fas ten screw (2).

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

• Clean sealing surfaces. • Mount gasket ( 1 ). • Mount oil return pipe (2). • Tighten screws (3). Bt· '::-, 8.5 Nm

• Tighten screw (1 ).

,",r· •· . 8.5 Nm ffil Attention' l.J2j Install tension-free.

4/6 Lubricating oil pipe DEUTZA. W 16-05-01 OBJ_DOKU-31098-001 .fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes/ Remark Value Oil return line on exhaust turbochar- A43 044 8.5 Nm Icier A43 046 Oil return line on crankcase 8.5 Nm

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

5/6 Lubricating oil pipe W 16-05-01 DEUTZA® OBJ_DOKU-31098-001 Im

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

Standard tools Collect leaking operating substances in suitable vessels and dispose of according [I] Special tools: to regulations. - Disassembly tool 02992127 Observe the appropriate operating instruc - Fitting compound tions for emptying and filling the engine. DE UTZ AP1908 II

Removing the oil return line

Fastening flange 2 O-ring 3 Oil return line 4 O-ring 5 Hexagon head screw 6 Hexagon head screw 7 Seal

0 ..,..... 4

rs; 50657 •0

• Unscrew screws (1 ). • Remove gasket (2).

1/6 Lubricating oil pipe W 16-05-01 DEUTZA. OBJ_DOKU-31099-001.fm

• Unscrew screw ( 1). •Pullout oil return line (2) in direction of arrow.

II © 506B1-0

• Remove flange ( 1) in direction of arrow. • Remove round sealing ring (2) with disassembly tool. • Visually inspect the component.

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

©U9.12Q12 2/6 Lubricating oil pipe A. W 16-05-01 DEUTZ OBJ_DOKU-31099-001.fm

Mounting the oil return line • Clean sealing surfaces. • Lightly coat new round sealing ring with DEUTZ AP1908 mounting compound. • Insert new O-ring ( 1 ).

• Clean sealing surfaces. • Lightly coat new round sealing ring with DEUTZ l I AP 1908 mounting compound. • Insert new O-ring (1 ). 01 • Insert flange (2) in direction of arrow.

I.,0 .:; 5068.5-0

• Clean sealing surfaces. • Mount oil return pipe ( 1 ). • Insert oil return line (1) in direction of arrow. • Fas ten screw (2).

~ 50686·0

3/6 Lubricating oil pipe W 16-05-01 DEUTZA. OBJ_DOKU-31099-001.lm

• Clean sealing surfaces. • Mount gasket ( 1 ). • Mount oil return pipe (2). • Tighten screws (3). :''· ,_., 8.5 Nm

• Tighten screw (1 ). f,-, :; 8.5 Nm liN Attention! li2J Install tension-free.

Technical Data

Tightening specifications ID no. Name Screw type Notes/ Remark Value Oil return line on exhaust turbochar- A43 044 8.5 Nm ger A43 046 Oil return line on crankcase 8.5 Nm

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

,:;J 0912012 6/6 High-pressure pump DEUTZA. W 17-01-04 OBJ_DOKU-31100-001.fm

Removing and installing the high-pressure pump

Standard tools: - Safety information/ User - Separating tool information wSpecial tools: - Special wrench 02992112 Danger! - Disassembly tool 02992127 Do not carry out work on the fuel system - Plugs/caps 01899144 when the engine is running. The fuel system is under high pressure - - Mirror Danger of death. - Marker pen, waterproof, ~ permanent The fuel pressure can continuously remain up to several 1OD 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. II Attention! Ensure utmost cleanliness for all work. Remove any paint residue and din par ticles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and natio nal specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Removing the high-pressure pump J '. u 1 High-pressure pump 2 Spacer 3 Hexagonal nut '., ·• .. -'~':f°'~ ' 4 Washer ... 5 O-ring 6 Hexagonal nut 7 O-ring

• 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 II

• 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 inter mediate gear

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

2/6 High-pressure pump A. W 17-01-04 DEUTZ OBJ_DOKU-31100-001 Im

• 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 sep arating tool. • Remove spacer (4). • Visually inspect the components.

• 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 DEUTZA. 0BJ_DOKU-31100-001.fm

Installing the high-pressure pump • Clean sealing surfaces. • 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.

II © 51436-0

• 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 © 51438-0

( 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 II

. h ressure pump. • Install hig -p t be visible. Markings mus atch. · must m Help marking heel ump gear w (1) Marking. hi _9 h-pressure. h-pressure P pump gear wheel Help marking_ h1g ear (2) and intermediate g 0

Attention! - h-pressure pump. Do not twist the h1g

• Serewon nuts (1 ). • Tighten nuts ( 1 ). ~-,., :, 21 Nm

• Install locking screw. ____ " Module 09

• Install fuel pipes. 1· e • Fit new h1gh-p. ressure21 in . .· Module .. - . , lu • Plug .in an d lock cable P g.

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

Technical Data Tightening specifications ID no. Name Screw type Not~s / Remark Value High-pressure pump gear wheel and Hold high-pressure pump A17 004 80 Nm high-pressure pump drive shaft oear wheeL A17 031 High-pressure pump on crankcase 21 Nm

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

1l 0912012 6/6 Injector W 19-01-01 OBJ_DOKU-31101-001 .fm

Removing and installing the injector

Standard tools - Safety information / User information rn Special tools: - Diagnostic tool SerDia 2010 Danger! - Assembly pliers 01899050 Do not carry out work on the fuel system - T orx tool set 01899092 when the engine is running. - Plugs/caps 01899144 The fuel system is under high pressure - - Lever tool 02992117 Danger of death. - Disassembly tool 02992127 The fuel pressure can continuously remain - Extraction tool 02992138 up to several 100 bar even after stopping - Slide hammer 02992294 the engine. Here the fuel pressure is only reduced if the fuel system is opened and the fuel can escape outside. II Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and natio nal specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Remove injector

1 Injector 2 Sealing disc 3 Clamping claw 4 Screw

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. II <'l 51243-0 The injector calibration depends on the installed injection system. The exact procedure can be taken from the listed documentation and must be obser ved.

'--.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.

• Unlock cable plug and remove. • 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

• Unscrew screw (2).

• 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.

;) 50<62-0 II

Attention! Do not brush off the nozzle tip of the iniec tor_ 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 DEUTZA. 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. Attention! Before installing the injector, combustion residue must be cleaned carefully from the bore on the cylinder head. Suck off dirt particles.

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. II

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 posi tion automatically. Otherwise renew the clip. L.,.• J Module 21 • Plug in and lock cable plug.

Technical Data Tightening specifications ID no. Name Screw tvoe Notes / Remark Value Observe order of Injector on cylinder head, clamping installation. A 19 001 30 Nm claw 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. II

6/6 Fuel filter DEUTZA. W 20-90-16 OBJ_DOKU-31102-001.fm

Fuel pre-filter

[I] Standard tools - Safety information / User information - 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. 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. II Attention! Ensure utmost cleanliness for all work. Remove any paint residue and din par ticles before disassembly. Clean the area around the components concerned carefully. Blow wet pans dry with compressed air. Observe the safety regulations and natio nal specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

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 A. DEUTZ OBJ_OO KU-31102-001 .fm

Fuel filter rn Standard tools - Safety information / User information - 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. 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. II Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and natio nal specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Fuel spare filter 2 Filter head 3 Pressure sensor 25 Nm 4 Hexagon head screw 42 Nm 5 0-ring [ll@f I Use new round sea ling ring.

Fuel line

Standard tools - Safety information I User information Special tools: - Operation manual - Hose clip pliers 01899037 - Spring band pliers 01899112 Danger! - Plugs/caps 01899144 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. II Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and natio nal specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Hose pipe 2 Hollow screw 20 Nm 3 Sealing ring 4 Clip 5 Holding tape 1~ I Use new sealing rings.

Attention! Ensure that the installation location is free from faults. Lay the hose pipe free from chafing and ten sion. - Dimension X

Supply pump (Fuel)

Standard tools - Safety information I User information [I] Special tools: - Plugs/caps 01899144 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 II escape outside.

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

Supply pump - Fastening • Screws i l 4 X M5-8.8 • 1 I Il .,,,

. I I -=-"ti © 5D547-D

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

2/2 Fuel pipes DEUTZA. W 21-04-01 OBJ_DO KU-31106-001 .fm

Removing and installing the rail

Standard tools: - Safety information / User [I] - Wrench insert size 14 information Special tools: - Long socket wrench insert 01899132 Danger! - Plugs/caps 01899144 Do not carry out work on the fuel system - Special wrench 02992112 when the engine is running. - Disassembly tool 02992127 The fuel system is under high pressure - Danger of death. - Assembly grease 01016496 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. II Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles before disassembly. Clean the area around the components concerned carefully_ Blow wet parts dry with compressed air. Observe the safety regulations and natio nal specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Removing the rail 4 1 Rail 2 High-pressure line 3 Injection line 4 Injection line 5 Torx screw 6 Spacer

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. II

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. • Unscrew screws (1). • Remove the rail (2). • Remove spacer (3). • Visually inspect the components.

if: 51411-0

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 connec tor. • 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.

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

II © 51412-0

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.

:!'.l 43253•1

• 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 pres sure limiting valve with assembly grease.

• Clean thread and sealing area of the rail. • Screw in pressure limiting valve (1 ). • Tighten pressure limiting valve.

f!;> '~::i 100 Nm

II © 51413-0

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 ).

~ 01415-0

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-pres sure 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.

• Tighten screws ( 1 ). 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. • Plug in and lock cable plug. IIJ@f I Ensure that the connection is perfect.

8110 Fuel pipes A. W 21-04-01 DEUTZ OBJ_DOKU-31105-001.frn

Technical Data

Tightening specifications ID no. Name Screw type Notes / Remark Value Injection line on rail and injector. Observe installation A21 003 high-pressure line on high-pressure Union nut regulation. 30 : )·~ Nm pump and on rail Use new line. Observe assembly A21 038 Rail on cylinder head 30 Nm specification. Lightly coat the thread A21 039 Pressure limiting valve on rail and sealing edge with 100 Nm assembly qrease. Lightly coat the thread A21 040 Pressure sensor on rail M18x1.5 and sealing edge with 70 Nm assembly grease. II For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of+/- 10% is permissible.

ti 0912012 10/10 Fuel pipes DEUTZA. W 21-05-05 OBJ_DOKU-31107-001.fm

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

Standard tools - Safety information/ User information Special tools: - Spring band pliers 01899112 - Plugs/caps 01899144 Danger! - Disassembly tool 02992127 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 II escape outside. Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles before disassembly. Clean the area around the components concerned carefully. Blow wet parts dry with compressed air. Observe the safety regulations and natio nal specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immedia tely before assembling. Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Removing the fuel line

1 Return line 2 Hose holder 3 Fuel line 4 Hose pipe 5 Pipe clip 6 Hexagon head screw 7 Spring band clip

Attention! Removed, missing and bent clips must be renewed. The clip must spring back to the hold posi tion automatically. Otherwise renew the clip. • Press in the clip (1) to the stop. • Pullout return line (2).

II © 51304-0

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

• Remove return line (1) from hose holder (2). • Unlock coupling plug (3) and pull off. • Unscrew screws (4).

• Loosen spring. band c I.ip ( 1} with spring. band pliers. • Pull off hose pipe (2). return line. • Remove mponents. • Visually .inspe ct the co

Mounting. the fuel line

tallation loca ,o Attention.· that I the .ins r n is free Ecsoce d from faults. th the spring ban • Position. the spnng band clip (1) w1 pliers. - Dimension X 2 •i~ .4-2• mm X • ,,Moun . t the hose pipe (2).

• Position res t u rn line. . hose holder ( ). rt return line ( 1) in 2 • lnse . ( )_ • Pos1t10.. n pipe clips 3

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

:!SJ 09/2012 3/6 Fuel pipes W 21-05-05 DEUTZA. OBJ_DOKU-31107-001.lrn

Attention! Removed, missing and bent clips must be renewed. The clip must spring back to the hold posi tion 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.

II © 51310-0

• Tighten screws ( 1) .

Technical Data Tightening specifications ID no. Name Screw e Notes I Remark Value A 12 095 Pipe clips. fastening 30 Nm

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

5/6 Fuel pipes W 21-05-05 DEUTZA. OBJ_DOKU-3 7 107-001 .fm

Removing and install the charge air line

[I] Standard tools

Remove charge air line

1 Charge air line 2 Seal 3 Hexagon head screw

• Remove fuel return line. • Unlock cable plug and disconnect. • Unscrew screws (1). • Remove charge air line (2). • Remove gasket (3). • Visually inspect the components.

Install charge air line • Clean sealing surfaces. • 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.

II © 504 15-0

• Mount charge air line (1). • Tighten screws (2). 1~ I Do not move gasket.

• Tighten the screws according to the tightening se quence. t'• ,,__ , 30 Nm B 4 2 6

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

• Plug in and lock cable plug. • Mount fuel return line.

5 1 3 7

~- ~0.!117-0

Technical Data Tightening specifications

ID no. Name Screw e Notes / Remark Value A2.2 030 Charge air line on c linder head 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 Charge air line W 22-01-01 DEUTZA. OBJ_DOKU-31108-00 t.fm

Removing and installing charge air manifold

101 Standard tools: l__!L_J - Spring band pliers 01899112

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 8 Hexagon head screw

·:e> 5U403-0

• Loosen spring band clips ( 1) with spring band pliers. • Unscrew screws (2). • Remove charge air manifold (3). • Remove gasket ( 4). • Visually inspect the component.

• I

Installing charge air manifold • Clean sealing surfaces. • Mount gasket ( 1 ). • Mount charge air manifold (2). • Fasten screws (3). • Tighten screws alternately. fJ,- ,_ ·:; 30 Nm

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

Technical Data Tightening specifications ID no. Name Screw e Notes/ Remark Value A22 046 Char e air manifold on char e air line 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 Charge air line W 22-04-01 DEUTZA. OBJ_OOKU-31109-001.fm

©-19120' 2 414 Charge air line DEUTZA. W 22-90-20 OBJ_DOKU-31110-001.Im

Pressure transmitter / temperature pressure transmitter (charge air)

Standard tools - Safety information / User information

- Fitting compound Attention! DEUTZ AP1908 Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles 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 immedia II tely before assembling.

1 Temperature sensor 2 Hexagon head screw 11 Nm 3 Hexagon head screw 30 Nm 4 Hexagon head screw 5 Nm 5 Pressure sensor 6 Console 7 Sealing ring 8 Hollow screw 18 Nm 9 Hose ring piece 242 Mounting compound

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

<,) 0912012 1/2 Charge air line W 22-90-20 DEUTZA. 0BJ_DOKU-31110-001.fm

Positions

5 Use mounting compound. Use new round sealing ring.

Intake nozzle (exhaust turbocharger)

~ Standard tools: l_JL_J - Spring band pliers 01899112

1 Intake nozzle 2 Spring band clip 3 Spring band clip 4 Hexagon head screw 13 Nm 5 Pipe clip 6 Pipe 7 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.

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

Charge air manifold

[I] Standard tools

1 Charge air manifold 2 Throttle valve 3 Seal 4 Hexagon head screw 30 Nm 5 Hexagon head screw 13 Nm 6 Seal 1~I Use a new gasket.

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

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A2.2 046 Char e air manifold on char e air line 30 Nm

212 Charge air line DEUTZA. W 22-90-55 OBJ_DOKU-31113-001.fm

Charge air line

Standard tools rn Special tools: - Spring band pliers 01899112

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 13 Nm g Pipe clip 10 Hexagon head screw 30 Nm 11 Hose pipe 12 Hollow screw 30 Nm 13 Sealing ring

Use a new gasket. ~

©;J9/'.i;'l)12 212 coolant pump DEUTZA. W 37-90-13 OBJ_DOKU-31114-001.fm

V-rib belt pulley

[I] Standard tools

1 V-rib belt pulley 2 Hexagon head screw 30 Nm

2/2 Coolant pump DEUTZA® W 37-90-06 OBJ_DOKU-31115-001 .fm

Drive components

[I] Standard tools

1 V-rib belt pulley 2 Hexagon head screw 20 Nm

f:l 0912012 212 Coolant pump A. W 37-90-13 DEUTZ OBJ_DOKU-31116-001.fm

V-rib belt pulley rn Standard tools

1 V-rib belt pulley 2 Adapter 3 Hexagon head screw 30 Nm

~0912012 2/2 Thermostat housing A. W 38-01-01 DEUTZ OBJ_DOKU-31117-001 .fm

Removing and installing the thermostat

[I] Standard tools - Operation manual

Collect leaking operating substances in suitable vessels and dispose of according to regulations. Observe the appropriate operating instruc tions for emptying and filling the engine. II

Removing the thermostat

Thermostat housing 2 Thermostat 2 4 Sealing ring 5 Screw plug 65 Nm 7 6 Seal 7 Hexagon head screw 8 Temperature sensor

• Drain, collect and dispose of coolant according to regulations • If present: Remove coolant hose from outlet nozzle. • Unscrew screws (1 ). • Remove thermostat housing (2) • Visually inspect the component.

11)51384-0

• Remove gasket (1 ). • Remove thermostat (2). • Visually inspect the components.

\•'

II © .51385-0

Installing the thermostat • Clean sealing surfaces. • Insert thermostat (1 ).

• Insert screws ( 1) . • Fix new gasket (2) to the thermostat housing with screws.

'.Q5138b-Q

2/4 Thermostat housing DEUTZA. W 38-01-01 OBJ_DOKU-31117-001.fm

• Mount thermostat housing (1). • Tighten screws (2). • Fasten screws (3).

• Tighten all screws ( 1 ). :;, '<:, 30 Nm

• If present: Push coolant hose onto outlet nozzle and fasten. • Fill cooling system according to the operating manu al. /_-.:_j Operation manual T \ l

\_0 '

<;) 5138B-O

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A38 001 Thermostat housin on cylinder head 30 Nm

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

C09'2012 4/4 Thermostat housing A. W 38-01-02 DEUTZ OBJ_DOKU-3111B-001.fm

Checking the thermostat (in the removed state)

10) Standard tools: IA) Danger! Thermometer l___LJ - ~ Risk of injury! Hot water and hot thermostat.

Checking thermostat

Thermostat housing

2 Thermostat 2 4 Sealing ring 5 Screw plug 65 Nm 7 6 Seal 7 Hexagon head screw 8 Temperature sensor

6 /, 4 I 5

• Measure beginning of stroke, dimension (a). • Note measured value, dimension {a).

- --a --~

1/4 Thermostat housing W 38-01-02 A. DEUTZ OBJ_DOKU-31118-001.fm

• 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 ther mostat. Do not touch the thermostat. The waler should be continuously stirred for an even temperature distribution. The temperature rise should not take place fas ter than 1°C/min. Otherwise the beginning of opening will be delayed accordingly. - Nominal value: II ,:':< 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: Stroke Given: Measured: Beginning of stroke, dimension (a) End of stroke, dimension (b) Calculation: Dimension (b) - dimension (a) Result: = stroke • Compare resull with setpoint value. - Nominal value: ',,,, 9 mm

,f, \1~1201/ 214 Thermostat housing DEUTZA. W 38-01-02 OBJ_DOKU-311 18-001 Jm

Technical Data Testing and setting data ID no. Name Additional Information Value P38 11 Thermostat, beginning of opening 86 ·c P38 13 Thermostat, stroke at 99 •c . minimum 9mm P38 14 Thermostat, stroke, test temperature 99 ·c

3/4 Thermostat housing W 38-01-02 DEUTZA® OBJ DOKU-31118-001.fm

~ 09!2012 414 Coolant pipes DEUTZA@ W 38-90-32 OBJ_DOKU-31119-001.fm

Line

Standard tools: [I] - Spring band pliers 01899112 Special tools: - Plugs/caps 01899144

Pipe 2 Spring band clip f"

3 Elbow 3 4 Hose pipe 5 Hexagon head screw 13 Nm 2 6 Support plate 7 Pipe clip 8 Hexagon head screw 8 Nm \\

Line rn Standard tools

1 Coolant line 10 Hexagon head screw 14 Nm

'<' 0912012 1/2 Coolant pipes W 38-90-32 DEUTZA. OBJ_DOKU-31120-001.fm

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

Line [I] Standard tools

1 Coolant line 10 Hexagon head screw 14 Nm 11 Hexagon head screw 14 Nm 12 Washer

~0912012 1/2 Coolant pipes W 38-90-32 DEUTZA. OBJ_DOKU-31121-001.fm

Pressure fan

00 Standard tools

Pressure fan 2 Hexagon head screw 30 Nm

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

Removing and installing the exhaust line

00 Standard tools

Removing exhaust line

Exhaust line 2 Seal 3 Hexagon head screw

• Remove turbocharger. ~·__:__ _; Module 43

• Remove cooler. ._j Module 41

• Unscrew all screws (1). • Remove exhaust line (2), • Remove gasket (3).

Installing exhaust line • Visually inspect the components. • Clean sealing suriaces. • Turn in screws (arrows). • Fasten new seal ( 1) with screws on exhaust line.

II © so,20-0

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

• Fasten ell screws (2).

• Tighten the screws according to the tightening sequence.

1~;- '. ·; 30 Nm 8 3 5

• Install the turbocharger. .. --... : ,' ·------...v Module 43 -'o • Install cooler_ ~ ~ ---~ L--JJ Module 41 ,-- \ Cl)

6 4 2 7

'1>0912012 2/4 Exhaust pipe DEUTZAu W 41 -01-01 OBJ_0OKU-31 123-001.lm

Technical Data Tightening specifications ID no. Name Screw type Notes I Remark Value Observe tightening A41 001 Exhaust line on cylinder head 30 Nm sequence

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

3/4 Exhaust pipe W 41-01-01 A. DEUTZ OBJ DOKU-311 23-001 .frn

4/4 Exhaust pipe DEUTZA. W 41-01-01 OBJ_DOKU-31124-001.fm

Removing and installing the exhaust line

[I] Standard tools

Removing exhaust line

Exhaust line 2 Seal 3 Hexagon head screw

• Remove turbocharger. ~-:. ./ Module 43

• Remove cooler. :._:,-; Module 41

• Unscrew a II screws ( 1). • Remove exhaust line (2). • Remove gasket (3).

;f.: 09i2012 1/4 Exhaust pipe W 41-01-01 DEUTZA. OBJ_DOKU-31124-007.frn

Installing exhaust line • Visually inspect the components. • Clean sealing surfaces. • Turn in screws (arrows). • Fasten new seal (1) with screws on exhaust line.

II ©50731·0

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

• Fasten all screws (2).

• Tighten the screws according to the tightening se quence.

:·:, ,. 30 Nm 8 1 3 5 • Install the turbocharger. L.) Module 43

• Install cooler. .:::.:) Module 41 ! C Ii _) 1;,J~ ,._J

6 4 2 7

.:; SO?J:,.o

Technical Data Tightening specifications

ID no. Name Screw type Notes / Remark Value Observe Lightening A41 001 Exhaust line on cylinder head 30Nm sequence

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

3/4 Exhaust pipe W 41-01-01 DEUTZA. OBJ_DOKU-31124-001 .fm

4/4 Exhaust gas recirculation DEUTZA. W 41-90-04 OBJ_DOKU-31125-001.fm

Connection (Crankcase housing, exhaust gas circulation, coolant line)

Standard tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. - Fitting compound Observe the appropriate operating instruc DEUTZ AP1908 tions for emptying and filling the engine.

1 Hose nozzles 2 O-ring 3 Hexagon head screw 20 Nm

[ll@rl Use new round sealing ring.

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

Compensator structure (Exhaust line)

[I] Standard tools

1 Compensator J 2 Seal 3 Hexagon head screw 20 Nm

Use a new gasket.

Attention! Check seal. Ensure that the installation location is free from faults. Install without tension (without torsional stresses) and do not pre-compress.

:I) 0912012 1/2 Exhaust pipe W 41-90-21 DEUTZA. OBJ_DOKU-31126-001.lm

•~ :JW/0',J 212 Exhaust gas recirculation DEUTZA. W 41-90-32 OBJ_DOKU-31127-001.frn

Line (Thermostat housing, exhaust gas circulation, coolant line)

Standard tools: Collect leaking operating substances in - T orx tool set 01899092 suitable vessels and dispose of according - Spring band pliers 01899112 to regulations. Special tools: Observe the appropriate operating instruc - Plugs/caps 01899144 tions for emptying and filling the engine.

1 Hose pipe 2 Spring band clip 3 Coolant line 4 Torx screw 10 Nm 5 Hexagon head screw 8Nm 6 Pipe clip 7 Seal 8 Rubber sleeve 9 Sealing ring 10 Screw plug 80 Nm

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

1/2 Exhaust gas recirculation W 41-90-32 DEUTZA. OBJ_DOKU-31127-001.fm

(S)091l012 2/2 Exhaust gas turbocharger DEUTZA. W 43-01-01 OBJ_DOKU-31128-001.fm

Removing and installing the turbocharger

[1] Standard tools

Removing turbocharger

1 Exhaust turbocharger 2 Seal 3 Hexagon head screw

• 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 DEUTZA. OBJ_DOKU-31128-001.fm

• Unscrew screws ( 1 ). • Remove turbocharger (2). • Remove gasket (3). • Visually inspect the component.

Installing the turbocharger

• Clean sealing surfaces. • Mount gasket (1 ). '" Mount turbocharger (2). • Fasten screws (3).

• Fasten screw (1). • Tighten screw (1). '> ':·- 30 Nm • Tighten screws (2). ~;•,. ; 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

2/4 Exhaust gas turbocharger DEUTZA. W 43-01-01 OBJ_DOKU-31128-001.fm

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A43 020 Turbocharger on exhaust line 30Nm

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

3/4 Exhaust gas turbocharger W 43-01-01 DEUTZA. OBJ_DOKU-31128-001.fm

Removing and installing the turbocharger

[I] Standard tools

Removing turbocharger

1 Exhaust turbocharger ._l I -.. 2 Seal 3 Hexagon head screw

• Remove intake nozzle. L.,_i Module 22

• Remove the lubricating oil line. • Remove lubricating oil return line. [_-> Module 16 • Unscrew screws ( 1 ). • Remove turbocharger (2). • Remove gasket (3). • Visually inspect the component.

1/4 Exhaust gas turbocharger W 43-01-01 DEUTZA. OBJ_DOKU-31129-001 .fm

Insta Iii ng the tu rboch arg er • Clean sealing surtaces. • Mount gasket ( 1). • Mount turbocharger (2). • Tighten screws (3). t'f<·,~::, 30 Nm

• Fit intake nozzle. L:.J Module 22

• Install lubricating oil line. • Install lubricating oil return line. II !_~_) Module 16

2/4 Exhaust gas turbocharger DEUTZA. W 43-01-01 OBJ_DOKU-3 1129-00·1J m

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A43 020 Turbochar er on exhaust line 30 Nm

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

C)09t2012 3/4 Exhaust gas turbocharger W 43-01-01 DEUTZA. OBJ_DOKU-31129-001.fm

Exhaust manifold ( exhaust turbocharger) rn Standard tools

Exhaust manifold 2 Clip 3 N~ 10Nm [~ I Note installation position.

-- 3

ca, 50389-0

Exhaust manifold (exhaust turbocharger)

[I] Standard tools

1 Exhaust line 2 Clip 9 Nm 3 Clip 9 Nm 4 Seal

~ Note installation position. EJ Use a new gasket.

3 4 2

Exhaust manifold (exhaust turbocharger) wStandard tools

1 Exhaust manifold J 2 2 Clip 3 Nut 10 Nm 1~ I Note installation position.

@0912012 2/2 Add-on parts A. W 44-01-01 DEUTZ OBJ_DOKU-31133-001.fm

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

Ii;) 50562-1

• Remove V-rib belt. .~. .! Operation manual • Unscrew screw (1). • Remove belt tightener (2). • Visually inspect the component.

1/4 Add-on parts W 44-01-01 DEUTZA. OBJ_OO KU-31133-001 .1m

Installing the belt tensioner • Mount belt tensioner (1 ). • Fasten screw (2). • Tighten screw (2).

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

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A44 041 Belt tightener on gear case 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 Add-on parts W 44-01-01 DEUTZA@ OBJ_DOKU-31133-001.fm

4/4 Generator A. W 44-02-01 DEUTZ OBJ_DOKU-31134-001 .fm

Removing and installing the generator (Clamping latch}

[I] Standard tools - Safety information / User information - Operation manual

Removing the generator

Clamping strap 2 Threaded piece 3 Hexagon head screw 4 Washer • 5 Hexagon head screw 6 Hexagon head screw 7 Spacing sleeve 8 Hexagon head screw 9 Hexagonal nut

• Disconnect the battery's negative terminal. • Remove plus cable. • Pullout cable plug (1).

• Loosen screw (1 ). • Hold nut (2). • Unscrew screw (3). • Loosen screws (4). • Swing generator (5) in direction of arrow. • Remove V-belt.

• Unscrew screw {1 ). • Remove generator (2). • Visually inspect the components.

Installing the generator • Mount generator ( 1 ). • Fasten screw (2). • Insert screw (3). • Screw on nut (4 ).

• 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

• Tighten screw (3) . .:'':,. ,_--. 42 Nm

• Tighten screw (4). t'>,_. , 30 Nm

• Plug in the cable plug ( 1 ). • Fit plus cable, • Connect !he battery's negative termina I.

3/4 Generator W 44-02-01 DEUTZA. OBJ_DOKU-31134-001 .fm

Technical Data Tightening specifications ID no. Name Screw tvoe Notes / Remark Value A44 012 Generator on console 42 Nm A44 015 Generator at clamping latch 30 Nm A44 017 Clamping latch on gear case 30 Nm

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

414 Generator A. W 44-02-01 DEUTZ OBJ_DOKU-31135-001.fm

Removing and installing the generator (Fastening parts)

[I] Standard tools

Removing the generator

1 Hexagon head screw 2 Hexagon head screw

• Remove V-rib belt L_:,,.J Operation manual • Disconnect the battery's negative terminal. • Remove plus cable. • Unlock cable plug ( 1) and disconnect.

• Unscrew screws ( 1 ). • Remove generator (2). • Visually inspect the components·.

Installing the generator • Mount generator (1). • Tighten screws (2). 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 2/4 Generator DEUTZA. W 44-02-01 OBJ_DOKU·31135-001.fm

Technical Data Tightening specifications ID no. Name Screw e Notes / Remark Value A44 012 Generator on console 42 Nm

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

3/4 Generator W 44-02-01 DEUTZA. OBJ_DOKU-31135-001. fm

G 0912012 4/4 Add-on parts DEUTZA® W 44-02-06 OBJ_DOK U-31136-001.fm

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

Standard tools [ml -Operation manual

- Packing compound DEUTZ OW 73

Removing the console

Console 2 Clamping pin 3 Hexagon head screw 4 Clamping sleeve 5 Hexagon head screw 244 Packing compound

• Remove V-rib belt.

/~_/ Operation manual • Remove generator (level 1). /~_j Module 44

• Unscrew screws (1). • Remove console (2). • Visually inspect the components.

-t) 0912012 114 Add-on parts W 44-02-06 DEUTZA. OBJ_DOKU-31136-001.fm

Mounting the console • Clean sealing surfaces.

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

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

'b": 50657•iJ

• Mount console ( 1) over the clamping pins. • Fasten screw (2). M8x85-10.9 • Fasten screws (3). M8x60-10.9

@09/2012 2/4 Add-on parts DEUTZA® W 44-02-06 OBJ_DOKU-31136-001 .Im

• Tighten all screws according to the tightening se quence.

0 f.t •~:) 30 Nm

• Mount generator (level 1 ). W Module 44 5 2 • Fit the V-rib belt according to the running direction .

Operation manual .1-:...) 4

6 ~ 50859•0 II

Technical Data Tightening specifications ID no. Name Screw e Notes I Remark Value A44 013 Console on crankcase/ ear case 30 Nm

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

4/4 Starter W 44-03-01 OBJ_DOKU-31137-001 .fm

Removing and installing the starter

[]] Standard tools

Removing the starter

1 Starter 2 Hexagon head screw

• Disconnect the battery's negative terminal. • Remove plus cable. • Unlock cable plug ( 1) and remove. • Remove cable ties.

• Unscrew screws (1). • Remove starter (2). • Visually inspect the component.

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 Starter DEUTZA. W 44-03-01 OBJ_DOKU-31137-001.fm

Technical Data Tightening specificatlons ID no. Name Screw · e Notes / Remark Value A44 001 Starter on connection housin 60 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 Starter W 44-03-01 DEUTZA. OBJ DOKU-31137-001.fm

Removing and installing the starter

[I] Standard tools

Removing the starter

1 Starter 2 Hexagon head screw

• Disconnect the battery's negative terminal. • Remove plus cable. • Unlock cable plug and remove. • Unscrew screws (1 ). • Remove starter (2). • Visually inspect the components.

Installing the starter • Insert starter ( 1 ). • Insert screws (2). • Tighten screws (2).

tj:-,c:::, 60 Nm

~ Attention! LJ2J L_ay the cables free from chafing and tension. • Plug in and lock cable plug. • Fit plus cable. II • Connect the battery's negative terminal.

Technical Data Tightening specifications ID no. Name Screw e Notes I Remark Value A44 001 Starter on connection housing 60 Nm

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

Is: 0912012 314 Starter W 44-03-01 A. DEUTZ OBJ_DOKU•31138-001.fm

Generator rn Standard tools

Generator 6 1 2 3 9 8 10 4 5 2 Fan 3 Spacing washer 4 Washer 5 Hexagonal nut 90 Nm 6 Voltage regulator 8 V-belt pulley 9 Ring 10 Ring

212 Parts to generator DEUTZA. W 44-90--42 OBJ_DOKU-31140-001.fm

Generator

[I] Standard tools

1 Generator 2 Voltage regulator 3 Hexagonal nut 90 Nm 4 Washer 5 V-rib belt pulley

@5134B-O

~ 0912012 1 /2 Parts to generator W 44-90-42 DEUTZA. OBJ_DOKU-31140-001.frn

~ 0912012 2/2 Engine mounting DEUTZA. W 46-90-15 OBJ_DOKU-31141-001 .fm

Engine mounting rn Standard tools

1 Holder . ~-,':,,, 2 Hexagon head screw 260 Nm 3 Stand foot 7 ~- 4 Hexagon head screw 200 Nm e~ 5 Hexagonal nut . 6 Washer 6~ ' \ , 7 Washer \,0., 0\

~ 0912012 112 Engine mounting W 46-90-15 DEUTZA. OBJ_DOKU-31141-001 Jm

Engine mounting

[I] Standard tools

1 Stand foot 2 Hexagon head screw 200 Nm 3 Washer

Engine mounting

[]] Standard tools

1 Stand foot 2 Hexagon head screw 200 Nm 3 Washer 4 Mount buffer 5 Bushing

2 ©51<1B60

{:;-09.'2012 212 Measuring instruments DEUTZA. W 51-90-20 OBJ_DOKU-31144-001.fm

Impulse transmitter (camshaft) rn Standard tools - Safety information I User information

Attention! Ensure utmost cleanliness for all work. Remove any paint residue and dirt par ticles 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 immedia II tely before assembling.

1 Impulse transmitter 2 Hexagon head screw 8,5 Nm

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

Os> 09/2012 1/2 Measuring instruments W 51-90-20 DEUTZA. OBJ_DOKU-31144-001.fm

Removing and installing the connection housing

[I] Standard tools

Removing the connection housing

1 Connection housing 2 Hexagon head screw 3 Bushing

• Remove flywheel. CJ Module 05 • Unscrew screws ( 1). • Remove connection housing (2). • Visually inspect the component.

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 bush ings.

• Tighten screws (1 ). • Tighten all screws ( 1) alternately. :"'· , .. 170Nm

• Install flywheel. _.... - ! Module 05

(i:) (J~."}(11/ 2/4 Connection housing DEUTZA. W 52-01-01 OBJ_DOKU-31145-001 .fm

Technical Data

Tightening specifications

ID no. Name Screw type Notes / Remart. Value Tighten diagonally oppo- A52 080 Connection housing on crankcase 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. II

4/4 Connection housing DEUTZA. W 52-01-01 OBJ_DOKU-31146-001.fm

Removing and installing the connection housing

[!] Standard tools

Removing the connection housing

1 Connection housing 2 Hexagon head screw 8,5 Nm 3 Cover plate 4 Hexagon head screw 5 Bushing

• Remove flywheel. Module 05

• Unscrew screws ( 1) . • Remove connection housing (2). • Visually inspect the component.

1/4 ConneCtl ·on housing w 52-01-01 DEUTZA. OBJ_OOKU-31146-00 1.fm .

Installing the conn ection housing

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

II © ~Ob72-0

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

crews (1 ). • Tighten s ( 1) alternately. • Tighten all screws . 170 Nm • Install flywheel.

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

Technical Data Tightening specifications ID no. Name Screwtvoe Notes / Remark Value Tighten diagonally oppo• A52 080 Connection housing on crankcase 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. II

3/4 Connection housing W 52-01-01 DEUTZA. OBJ_DOKU-31146-001.fm

,e; 0912012 414 Connection housing DEUTZA. W 52-01-01 OBJ_DOKU-31147-001 .Im

Removing and installing the connection housing

[I] Standard tools

Removing the connection housing

Connection housing 2 Hexagon head screw 3 Bushing

• Remove flywheel. !_::_) Module 05 • Unscrew screws ( 1). • Remove connection housing (2). • Visually inspect the component.

Installing the connection housing • Clean contac1 surfaces.

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

• Position connection housing ( 1 )_ • Centre connection housing over the clamping bush ings.

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

,".r· •.- . 170 Nm

• Install flywheel. -- ~-:_) Module 05

2/4 Connection housing A. W 52-01-01 DEUTZ OBJ_DOKU-31147-001 .Im

Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Tighten diagonally oppo- A52 080 Connection housing on crankcase 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. II

3/4 Connection housing W 52-01-01 DEUTZA. OBJ_OOKU-3)147-001 Im

4/4 Connection housing A. W 52-01-01 DEUTZ OBJ_DOKU-31148-001 .frn

Removing and installing the connection housing rn Standard tools

Removing the connection housing

1 Connection housing 2 Hexagon head screw 3 Bushing

2 3

@51360-0

• Remove flywheel. G Module 05 • Unscrew screws ( 1). • Remove connection housing (2). • Visually inspect the component

1/4 Connection housing W 52-01-01 DEUTZA. OBJ_DOKU-31148-D01 fm

Installing the connection housing • Clean contact surfaces. r:::;;i Make sure the clamping bushings (1) are EJ in place.

• Position connection housing ( 1 ). • Centre connection housing over the clamping bush ings.

• Tighten screws (1) • Tighten all screws (1) alternately ,,,.,,., 170 Nm

• Install flywheel. :_j Module 05

21<1 Connection housing DEUTZA. W 52-01-01 OBJ_OOKU-31148-001 .Im Technical Data Tightening specifications

ID no. Name Screw type Notes / Remark Value Tighten diagonally oppo- A§2 080 Connection housing on crankcase 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 II

~090012 3/4 Connection housing W 52-01-01 DEUTZA. OBJ _DO KU-31148-001 Im

4/4 Connection housing A. W 52-01-01 DEUTZ OBJ_OOKU-31149-001 .frn

Removing and installing the connection housing rn Standard tools

Removing the connection housing

Hexagon head screw 2 Bushing

• Remove flywheel. W Module 05 • Unscrew screws (1 ). • Remove connection housing (2). • Visually inspect the component.

1/4 Connection housing W 52-01-01 DEUTZA. OBJ_DOKU-31149-001.fm

Installing the connection housing • Clean contact surfaces r::;:;;;i Make sure the clamping bushings ( 1) are ~ inplace

• Position connection housing ( 1 ). • Centre connection housing over the clamping bush ings.

• Tighten screws (1 ). • Tighten all screws (1) alternately. 170 Nm

• Install flywheel. _-::J Module 05

2/'1 Connection housing DEUTZA. W 52-01-01 OBJ_DOKU-31149-001.fm

Technical Data Tightening specifications

ID no. Name Screw type Notes / Remar1c: Value Tighten diagonally oppo- A52 080 Connection housing on crankcase 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. II

!: 0912012 314 Connection housing W 52-01-01 A. DEUTZ OBJ_DOKU-31149-001 fm

~ 0912012 4/4 Connection housing DEUTZA@ W 52-90-53 OBJ DOKU-31150 001.fm

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.

2 3

Removing and installing the glow plugs

Standard tools: - Safety information/ User - Crowfoot wrench size 10 information Special tools: - Torque handle 01899184 - Insert holder long 01899185

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 1/4 Start aid W 63-02-01 DEUTZA. OBJ_DOKU-31151-001.tm

• Unscrew glow plugs ( 1) . • Visually inspect the components.

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

214 Start aid DEUTZAe W 63-02-01 OBJ_DOKU-31151-001.fm

Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A63 032 Glow plug on cylinder head 13.5 Nm A63 033 Connecting rail on glow plug Use new lock nut 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. II

3/4 Start aid W 63-02-01 DEUTZA® OBJ DOKU-31151-001.tm

~ 09/2012 41'1 Exhaust gas treatment DEUTZA. W 71-90-51 OBJ_DOKU-31152-001.fm

Console rn Standard tools

1 Console 2 3 Hexagon head screw 60 Nm

il.>09/201~ 1/2 Exhaust gas treatment W 71-90-51 A. DEUTZ OBJ_DOKU-31152-001 Im

212 Hydraulic pump drive DEUTZA® W 83-02-01 OBJ_DOKU-31153-001.fm

Removing and installing hydraulic pump drive

Standard tools

- Packing compound DEUTZ DW 73

Removing hydraulic pump drive

Hydraulic pump drive 24-4 I_ 4 3 Hexagon head screw 4 Hexagon head screw 244 Packing compound

• Unscrew screws ( 1). • Unscrew screws (2). • Remove hydraulic pump drive (3).

1 /4 Hydraulic pump drive W 83-02-01 DEUTZA. 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 screws (2). • Fasten screws (3).

• Tighten all screws according to the tightening se quence

P:, 30 Nrn 2

(~) :1113S-O

~ :J9.12Cl2 2/4 Hydraulic pump drive DEUTZA. W 83-02-01 OBJ_DOKU-31153-001.lm Technical Data Tightening specifications ID no. Name Screw type Notes"/ Remark Value Hydraulic purnp on crankcase/gear A83 003 case 30Nm

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

3/4 Hydraulic pump drive W 83-02-01 DEUTZA® 0 BJ DOK U-31153-001 fm

8 Special tools II

Orders

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

1!:10912012 2/10 Special tools DEUTZA. W 49-01-01 OBJ_DOKU-31154-001 frn

01899031 Pressure pump Checking cooling system for leak-tightness

01899037 Hose clip pliers Loosen hose clips and fasten II

01899050 Assembly pliers Removing valve shaft seals

3110 Special tools W 49-01-01 DEUTZA. OBJ DOKU-31154-001 fm

01899062 V-belt tension measuring device 150 to 600 N Check V-belt tension

01899092 T orx tool set II 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

~ 49342-0

4/10 Special tools DEUTZA. W 49-01-01 OBJ_DOKU-31154-001.fm

01899103 Pricker Removing rotary shaft lip seal

01899110 Assembly lever e. g. removing and installing valves II

01899112 Spring band pliers 320 mm Tighten spring clamp

5/10 Special tools A. W 49-01-01 DEUTZ OBJ_DOKU-31154-001 fm

01899132 Socket wrench insert long Installing ancl removing pressure sensors (rail pressure, oil pressure, fuel pressure)

lil 49357-0

01899144 Stoppers/caps II 1 set of differently-sized stoppers and caps Sealing openings on the fuel system ...... di ..

ls) 43663-0

01899184 Torque handle 0.6 - 1.5 Nm

t ··~..

~0912012 6110 Special tools DEUTZA. W 49-01-01 OBJ_ DOK U-31154-0 01.fm

01899185 Insert holder Drive square 1/4" Drive hexagon 1/4"

02992112 Special wrench Wrench size 17, II Removing and installing high-pressure lines

02992117 Lever tool Removing the injector

7/10 Special tools W 49-01-01 DEUTZA. OBJ_DOKU-31154-001 .frn

02992127 Disassembly tool Removing O-ring

02992138 Puller II (in conjunction with slide hammer 02992294) Removing jammed injector sealing ring

'1; 35,37. 1

02992214 Assembly tool Installing crankshaft sealing ring (flywheel side)

. -,

f ) 091~012 8/10 Special tools A. W 49-01-01 DEUTZ OBJ_0OKU-31154-001.fm

02992294 Slide hammer (in conjunction with disassembly device 02992137) Disassembling injector sealing ring

02992301 Separating tool Removing metal sheet lubricating oil pan from crank II case

9/10 Special tools W 49-01-01 DEUTZA. OBJ _DOKU-31154- 001 fm

:SJ 09/201 2 10/ 10