Operation Manual BVM 640

0297 …
4. 6.
✂
3.
✂
Operating Instructions
5. R/S/BVM 640
✂
1. R/S/BVM 640
✂
✂
6.
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R/S/BVM 640
0299 8179 en
Engine Number:
Please enter your engine number here. This will help us to serve you
better in questions of repairs, spare parts and after-sales service
generally.
We reserve the right to make technical alterations to the drawings

and particulars in this documentation package, if this should be-
come necessary to improve the engines. Reprints and duplication of
any kind, either in whole or in part, require our written permission.
R/S/BVM 640
This documentation is intended for the following engine.
● Engine type:
● Application:
● System name:
● Rating: kW
● Speed: / min
● Commissioning on:
Please enter the relevant data. This will make it easier for us to help you in questions involving repairs,
spare parts and after-sales service in general.
This documentation package is to be presented to the Service Partner responsible every time a service
job is carried out.
Imprint:
DEUTZ AG
Service-Technik
Servicedokumentation
Deutz-Mülheimer Straße 147–149
D-51057 Cologne
Tel.: (+49 2 21) 8 22-0
Fax: (+49 2 21) 8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reserved
(1) 0801 ©
Ordering No. 0299 8179 en
Page II 0299 6884-0125 © 0801

R/S/BVM 640
● Please read all the information contained in this manual, and follow the instructions carefully. You will avoid
accidents, retain the manufacturer’s warranty, and will be able to use a fully functional and operational
engine.
● This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as defined
by the equipment manufacturer (intended use). Any other use shall be construed as not intended. The
manufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solely
by the user.
● The term „intended use“ shall also include compliance with the operating, maintenance and repair conditions
specified by the manufacturer. The engine may be used, maintained and repaired only by persons who are
familiar with the work concerned and who have been properly informed of the risks involved.
● Make sure that these operating instructions are available to everyone involved in operating, maintaining, and
repairing the engine, and that they have all understood the contents.
● Non-compliance with these operating instructions may result in engine malfunctions and even damage or
injury to persons; the manufacturer will accept no liability in such cases.
● Proper maintenance and repair work depends on the availability of all requisite equipment, tools and special
implements, all of which must be in perfect condition.
● Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handled
properly.
● The relevant accident prevention regulations and other generally recognized rules relating to safety
engineering and health and safety at work must all be complied with.
● Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG are
used.
● Engine repairs must correspond to the intended use. In the event of modification work, only parts approved
by the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine will
preclude any liability of the manufacturer for resultant damage.
© 0801 0299 4108-0125 Page III

Forword R/S/BVM 640
Dear customer,
The engines of the DEUTZ brand have been developed for a broad spectrum of applications. A
comprehensive range of different variants ensures that special requirements can be met for the
individual case involved.
Your engine has been equipped to suit your own particular installation, and accordingly not all of the
devices and components described in these operating instructions will actually be fitted to your engine.
We have endeavoured to present the differences involved as clearly as possible, to make it easier for
you to find the operating and maintenance instructions you need for your own particular engine.
Please read this manual before you start up your engine, and follow the operating and maintenance
instructions meticulously.
If you have any questions, just get in touch with us, and we will be pleased to answer them for you.
Yours sincerely,
DEUTZ AG
Page IV 0299 4108-0125 © 0801

R/S/BVM 640 General
DEUTZ engines
are the culmination of long years filled with research and development work. The in-depth know-how
thus acquired, in conjunction with high standards of quality, is your guarantee for engines manufactured
for long lifetime, high reliability and low fuel consumption. And of course, stringent criteria of
environment-friendliness are met as well.
Care and maintenance

are crucial factors in ensuring that your engine satisfactorily meets the requirements involved.
Compliance with the specified maintenance intervals and meticulous performance of care and
maintenance work are therefore absolutely essential. Special attention must be paid to any more
critical operating conditions deviating from the norm.
DEUTZ AG
In the event of malfunctions, or if you need spare parts, please contact one of our responsible service
agencies. Our trained and qualified staff will ensure fast, professional rectification of any damage,
using original parts.
Original parts from DEUTZ AG have always been manufactured to the very latest state-of-the-art.
You will find details of our after-sales service at the end of these operating instructions.
Careful when the engine is running!

Carry out maintenance or repair jobs only when the engine is at a standstill. If you remove any protective
features, fit them back in position after completing your work. Always wear tight-fitting clothing if you
are working on the engine while it is running.
Safety
You will find this symbol next to all safety instructions. Follow these meticulously. Pass on all safety
instructions to your operating staff as well. In addition, comply with the statutory general safety and
accident prevention regulations applying in your country.
Instruction
You will find this symbol next to instructions of a general nature.
Follow these instructions carefully.
Asbestos
The seals and gaskets used in this engine are asbestos-free. Please use the appropriate spare parts
for maintenance and repair jobs.
© 0801 0299 4108-0125 Page V

R/S/BVM 640
Page VI 0299 4108-0125 © 0801

R/S/BVM 640 Contents
0 Introduction
Impressum, Forword, Contents
1 Guide to this manual
1.1 General
1.2 Trouble-shooting
1.3 Planned maintenance
1.4 Ordering of spare parts
1.5 Specification Data
1.6 Job Card No.
1.7 Standard tools
1.8 Special tools
1.9 DEUTZ Assembly Groups / Job Cards in Maintenance Groups of System 333
2 Layout and description of engine
2.1 Cylinder head

2.2 Drive mechanism
2.3 Crankcase
2.4 Engine control
2.5 Governor
2.6 Exhaust gas system / Charging
2.7 Fuel system
2.8 Lube oil system
2.9 Coolant system
2.10 Compressed air system
2.11 Monitoring system
2.12 Other components
2.13 Engine assemblies and subassemblies
2.14 Longitudinal section through engine
2.15 Cross section through engine
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Contents R/S/BVM 640
3 Technical data
3.1 Model designation

3.2 Designation of engine ends and sides and related definitions
3.3 Basic data
3.3.1 Design data
3.3.2 Operating data
3.3.3 Setting data for engine safety switches
3.4 Net weight of main engine components
3.5 Tightening specification for heavy-duty bolts (Screws and nuts)
3.5.1 Tightening schedule
3.5.2 Tightening procedure
3.5.3 Information on the hydraulic tool for annular nuts
3.6 Sealing compounds, locking compounds, lubrication compounds,
heat conductor compounds
4 Operating the engine
4.1 Preparations for commissioning the engine

4.1.1 Preparations for commissioning the engine on distillate fuel
4.1.2 Preparations for commissioning the engine on heavy fuel or blended fuel
4.2 Commissioning and reversing the engine
4.2.1 Commissioning
4.2.1.1 Running the engine on distillate fuel
4.2.1.2 Running the engine on heavy fuel or blended fuel
4.2.2 Reversing the engine
4.2.3 Engine starting conditions
4.3 Attendance in service
4.4 Engine stoppage/layoff
4.4.1 Running the engine on distillate fuel
4.4.2 Running the engine on heavy fuel or blended fuel
4.5 Emergency operation
4.5.1 Operating the engine by means of emergency control
4.5.1.1 Starting the engine
4.5.1.2 Speed adjustment
4.5.1.3 Stopping the engine
4.5.1.4 Reversing the engine
4.6 Taking combustion indicator diagrams
4.7 Running in the engine
4.8 Running the engine with defective turbocharger
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R/S/BVM 640 Contents
5 Engine media systems
5.1 Fuel system

5.1.1 Legend for piping diagrams
5.1.2 Piping diagram for distillate fuel and blended fuel
5.1.3 Piping diagram for heavy fuel, open system
5.1.4 Piping diagram for heavy fuel, closed system
5.2 Lube oil system
5.2.2 Low-level tank
5.2.3 High-level tank
5.3 Coolant system
5.3.2 Coolant system without mounted pump
5.3.3 Coolant system with mounted pump
5.3.4 Coolant system with mounted pump and second pump as raw-water pump
5.4.2 Pneumatic diagram (BVM)
5.4.3 Pneumatic diagram (SBVM)
5.4.4 Pneumatic diagram (RBVM)
5.5 Injection pump plunger hydraulic seal
5.5.2 Fuel feed pump, separate valve seat lubrication
5.6 Injection nozzle cooling
5.6.2 Injection nozzle cooling
5.7 Symbols used in piping diagrams (Definitions to DIN 30600)
5.7.1 Piping
5.7.2 Shut-off fittings
5.7.3 Accessories
5.7.4 Heat exchangers
5.7.5 Containers
5.7.6 Machinery
5.7.6.1 Driving machines
5.7.6.2 Driven machines
5.7.7 Water heat exchangers
5.7.8 Measuring and control
5.7.9 Energies
© 0100 0299 6462-0125 Page III

Contents R/S/BVM 640
6 Expendables
7 Operational malfunctions, and how to correct
7.1 Table of operational malfunctions

7.2 General
7.3 Trouble Chart
8 Maintenance schedules and Job Cards
8.1 Maintenance schedules

8.1.1 Initial maintenance jobs
8.1.2 Daily checking and maintenance jobs
8.1.3 Periodic jobs
8.1.4 Instructions regarding periodic jobs to be carried out on engines running for up to
300 hours/year
8.2 List of Job Cards
8.3 Job Cards
00.00.00 General
01.00.00 Cylinder head
02.00.00 Drive mechanism
03.00.00 Crankcase
04.00.00 Engine control
05.00.00 Governor
06.00.00 Exhaust gas system / Charging
07.00.00 Fuel system
08.00.00 Lube oil system
09.00.00 Coolant system
10.00.00 Compressed air system
11.00.00 Monitoring system
12.00.00 Other components
9 Sundry other instructions
Service
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R/S/BVM 640 General
1 Guide to this manual
1.1 General
Surely you expect high degrees of reliability and availability of your DEUTZ engine as prerequisites for its
economical application. Great importance was attached to these properties in the course of the engine´s
development. However, these properties can be upheld during the engines entire lifespan only if the mainte-
nance and servicing jobs described in this Manual are carried out punctually and fully.
It its therefore essential that you become well acquainted with the contents of this Manual not only before
commissioning the new engine, but also to use it as a source of information for maintaining the high value of
the machine.
All safety precautions and regulations have been observed in the design, choice of materials and manufac-
ture of your engine. This high degree of safety and reliability will be maintained if the servicing jobs are fully
performed according to schedule by properly trained personnel, and if all guards and protective devices
removed for carrying out work on the engine are afterwards refitted.
When servicing, it is essential to observe the relevant regulations regarding accident prevention and general
safety.
The Maintenance Schedules give information concerning the work involved at the prescribed intervals.
The Job Cards (Chapter 8) give detailed instructions for carrying out the work. The Job Cards are arranged
in accordance with Maintenance Groups as per the Planned Maintenance System 333 *. In Chapter 1.9 is an
alphabetical Index of DEUTZ Assembly Groups together with the relevant Job Cards Nos. and Maintenance
Groups.
*Institut für Schiffsbetriebsforschung, Flensburg
1.2 Trouble-shooting
Should troubles and faults of any kind arise on the engine, please refer to Chapter 7, “Trouble-shooting”.
The Trouble Chart lists various potential causes for a certain fault, gives brief instructions for providing possi-
ble remedies, and refers to the Manual Section concerned an the Job Card Nos, containing further details for
carrying out the work involved.
1.3 Planned maintenance
Keep a regular record of the engine running hours and observe the schedule for maintenance and servicing
accordingly.
The Maintenance Schedule contains details of the maintenance work involved and the relevant Jab Card
Nos.
Carry out the work detailed on the Job Card.
1.4 Ordering of spare parts
The Spare Parts Catalogue associated with this Instruction Manual contains the Part Nos. for the ordering of
parts, and also design details, where necessary.
The Spare Parts Catalogue is arranged in accordance with DEUTZ Assembly Group Nos.
Detailed particulars on how to place a spare parts order can be found in the introduction to the spare parts
list.
1.5 Specification Data
Technical engine data, engine operating data and setting data for monitoring units are not provided in the
Job Cards. They can be found under ”Technical Data”, Chapter 3.
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General R/S/BVM 640
1.6 Job Card No.

The Job Cards are designated by a Job Card Number (e.g. 01.02.03), which is divided into three groups or
digits. These Job Card Numbers can be connected to another Job Card – if the checking, maintenance or
repair work involved so requires.
Typical Job Card No.: 01.02.03, where:
01 = Maintenance Group = Cylinder head
02 = Subassembly = rocker arm bearings

03 = Serial No. of card
1.7 Standard tools

The term ”Standard tools” signifies all tools which are normally contained in a toolbox:
Hammer Chisel
Rubber mallet Set of ordinary wrenches
Set of box wrenches Small water tube pliers
Srewdriver Combination pliers
Nippers Tape rule
Scriber Iron saw
Various Files Mandrel
Centre punch Hex. wrench
Socket-head wrench Non-fraying rags
Three-square scraper Grease gun
Wire brush
1.8 Special tools

Special fitting tools and devices, normally supplied along with the engine, are listed in our Spare Parts Cata-
logue under the Assembly Group Nos. 49 and 59.
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R/S/BVM 640 General
1.9 DEUTZ Assembly Groups / Job Cards in Maintenance Groups of System 333
Assembly Group Job Card Maintenance Group

87 Air cleaner 06.03.11 06 Exhaust gas system / Charging
87 Air intake cleaner 06.03.11 06 Exhaust gas system / Charging
15 Automatic Back-Flushing Filter 08.09.02 08 Lube oil system

02.03.01
02.03.02
06 Big-end bearing 02.03.03 02 Drive mechanism
02.05.01
02.06.01
17 Bleeding the fuel system 07.03.02 07 Fuel system

63 Brake drum 12.04.02 12 Other components
04.05.01
04.05.02
10 Camshaft 04 Engine control
04.06.01
04.06.02
04.01.01
10 Camshaft bearing 04 Engine control
04.01.02
15 Centrifugal oil cleaner 08.13.01 08 Lube oil system
06.04.01
58 Charge (boost) air 06 Exhaust gas system / Charging
06.04.02
87 Charge (boost) air system 06.02.01 06 Exhaust gas system / Charging
38 Coolant 09.01.01 09 Coolant system
37 Coolant 09.00.01 09 Coolant system
63 Coupling/clutch 12.04.01 12 Other components
11.05.01
48 Crankcase oil mist detector 11 Monitoring system
11.05.02
09 Crankcase vent 03.09.01 03 Crankcase
02.03.02
02.04.01
05 Crankshaft bearing 02 Drive mechanism
02.07.01
02.08.01
04.11.01
05 Crankshaft gear 04 Engine control
04.11.02
05 Crankweb deflection 02.02.01 02 Drive mechanism
01.04.01
01.08.01
08 Cylinder head 01 Cylinder head
01.09.01
01.10.01
03.02.01
03.03.01
04 Cylinder liner 03.04.01 03 Crankcase
03.04.02
03.05.01
32 Dust collector 10.03.02 10 Compressed air system
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General R/S/BVM 640
41 Exhaust manifold 06.01.01 06 Exhaust gas system / Charging
01.05.02
01.05.03
08 Exhaust valve 01 Cylinder head
01.05.05
01.07.03
48 Float switch 11.07.01 11 Monitoring system

48 Flow switch 11.01.03 11 Monitoring system
05 Flywheel 04.09.01 04 Engine control
85 Flywheel brake 12.05.01 12 Other components

20 Fuel duplex filter 07.10.01 07 Fuel system
86 Fuel pressurestat 07.03.04 07 Fuel system
05.04.02
29 Governing linkage 05.04.03 05 Governor
05.04.04
05.00.01
05.02.01
05.03.01
05.03.02
05.03.04
27 Governor 05 Governor
05.03.11
05.03.12
05.03.14
05.04.01
05.04 06
04.15.01
09 Governor drive 04 Engine control
04.15.02
02.16.01
48 Hydraulic tool for annular nuts 02.16.02 02 Drive mechanism
02.16.03
09 Idler gear 04.04.01 04 Engine control
07.01.01
07.02.04
07.03.01
17 Injection pump 07.04.01 07 Fuel system
07.04.02
07.04.03
07.06.01
08 Inlet valve 01.05.01 01 Cylinder head
86 Lube oil filter, valve seat lubrication 07.03.05 07 Fuel system
14 Lube oil pressurestat 08.11.01 08 Lube oil system

08.03.01
14 Lube oil pump 08 Lube oil system
08.04.01
15 Lube oil sample 08.01.01 08 Lube oil system
08.02.01
15 Lube oil system 08 Lube oil system
08.02.02
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R/S/BVM 640 General
02.03.02
02.04.01
02 Main bearing 02 Drive mechanism
02.07.01
02.08.01
48 Main bearing temperature detector 11.08.01 11 Monitoring system
05 Drive mechanism 02.01.01 02 Drive mechanism
48 Overspeed protection 11.03.01 11 Monitoring system
02.09.01
02.10.01
07 Piston 02.10.02 02 Drive mechanism
02.10.04
02.14.01
07 Piston pin 02.12.01 02 Drive mechanism
32 Compressed air system 10.01.01 10 Compressed air system
32 Pressure reducing 10.06.01 10 Compressed air system
32 Pressure switch 11.01.02 11 Monitoring system
21 Pulsation damper 07.03.04 07 Fuel system
14 Pump chest 04.14.01 04 Engine control
56 Pneumatic injection pump on/off control 05.07.01 05 Governor

01 Relief valve 03.01.01 03 Crankcase
11 Rocker arm 01.02.02 01 Cylinder head
04.07.01
10 Reversing system 04.07.02 04 Engine control
04.07.03
05 Safety regulations 02.00.01 02 Drive mechanism
31 Safety valve 01.12.01 01 Cylinder head
08 Shut-off valve 01.08.02 01 Cylinder head
07 Small-end bush 02.13.01 02 Drive mechanism

27 Speed governor see “Governor”
32 Starting aid master valve 10.03.11 10 Compressed air system
10.02.01
30 Starting pilot air distributor 10 Compressed air system
10.02.02
01.11.01
31 Starting valve 01 Cylinder head
01.11.02
11 Tappet 04.02.01 04 Engine control
48 Temperature switch 11.01.01 11 Monitoring system
11.01.04
48 Thermocouples 11 Monitoring system
11.01.05
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General R/S/BVM 640

06.05.01
06.06.01
43 Turbocharger 06.12.01 06 Exhaust gas system / Charging
06.13.01
06.13.02
05 Turning wheel 04.09.02 04 Engine control
11 Valve clearance 01.01.01 01 Cylinder head
08 Valve guide 01.06.01 01 Cylinder head
08 Valve seat insert 01.07.02 01 Cylinder head

16 Valve seat lubrication 08.14.01 08 Lube oil system
34 Vibration damper 12.01.01 12 Other components
48 Water detector in charge air pipe 11.06.01 11 Monitoring system
Chapter 1 - Page 6 0299 6463-0125 © 0201

R/S/BVM 640 Description
2 Layout and description of engine
2.1 Cylinder head

The cylinder head is held down on the liner by 8 studs with annular nuts that are hydraulically tightened.
Access to the inlet and exhaust valves plus drive is gained by removing the rocker chamber cover on relea-
sing 4 tommy screws.
Each head incorporates two inlet and exhaust valves with rotators, one injector and one starting valve. Relief
and indicator valves may also be provided.
When using heavy fuel oil, a gate valve amy be provided for isolating the exhaust valve cages from the coo-
lant, permitting the cages to be removed complete with rotators. If no such valve is provided, the coolant
must be drained before cage removal.
2.2 Drive mechanism
The single-piece crankshaft is fitted in underslung arrangement. Its end float is controlled by a locating bea-
ring in the timing gear chest. Where external thrust bearings (for accomodating propeller thrust) are provi-
ded, the locating bearing segments are ground clear off the crankwebs.
The shaft journals and crankpins are hardened and run in bearings of the split (shell) type.
Mass balancing weights are fitted on the shaft as determined by the rated engine speed.
The two-piece pistons are provided with four compression rings and one oil control ring. Two compression
rings are located in the upper piston part, the remaining two compression rings and the oil control ring in the
lower part above the full-floating piston ring.
The annular nuts of cylinder head, main bearing, big-end bearing and foundation studs are tightened hydrau-
lically.
2.3 Crankcase
The liner flanges are seated on a gasket ring fitted on the single-piece crankcase.
After removing the large crankcase doors, easy access is gained to the crankcase interior. On one crank-
case side there may be a relief valve as an outlet for a possible explosion.
The oil sump below the crankcase is of the “dry” type.
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Description R/S/BVM 640
2.4 Engine control

Driven from the gear on the crankshaft at the engine’s driving end, the timing gear train in ist turn drives -
trough idler gears - the camshaft gears and the governor.
The camshafts are driven at half engine speed. As determined by the firing order, the shafts control the inlet
and exhaust valves, the injection pumps and - through a special cam - the starting pilot air distributor.
The camshaft is of the multi-piece type, each piece controlling one cylinder. The bearings are of the split
(shell) type. The shaft cams and bearing points are surfacehardened.
While in uni-directional engines, the camshaft is axially held by a locator ring at the engine’s driving end,
direct-reversing engines use a reversing mechanism in the form of an air-oil relay.
Mounted on the pump chest at the engine’s free end are one or two lube oil pumps, gear-driven by the
crankshaft.
The flywheel or turning wheel (flyring), as the case may be, is flanged to the crankshaft at the engine’s dri-
ving end.
2.5 Governor
Speed control etc. on a stationary engine is possible from an engine-mounted control unit. Marine engines
use a seperate local control unit and optionally also a remote control unit.
The speed governor is of the hydraulic type, the stopping device of the pneumatic type.
2.6 Exhaust gas system / Charging
Charging is performed by an exhaust-gas turbocharger. The cooling equipment for the exhaust gas turboch-
arger is connected to the engine’s cooling system. The bearings of the exhaust gas turbocharger are self-
lubricated. Downstream of the exhaust gas turbocharger is an intercooler, where the charging air is cooled
with liquid coolant.
Cleaning devices for the turbine (in heavy-oil mode) and compressor sides of the exhaust gas turbocharger
are fitted.
2.7 Fuel system
The engine can run on diesel fuel, MDF destillate, MDF-blend or HFO (heavy fuel oil), depending on the
equipment provided.
Each cylinder has ist own injections pump, using direkt fuel injection an helical port control by the plunger.
The plungers have a hydraulic seal preventing fuel leaking past them down into the pump’s oil sump.
The injectors use multi-rifice nozzles ensuring perfect fuel atomization into the combustion chamber.
The fuel filter is of the change-over type an fitted with strainer-type elements. The filter can be heated if
required by the type of fuel or engine application.
2.8 Lube oil system
The lubricating circuit is supplied by an engine-mounted pump with oil from a high or low-level tank.
Where a high-level tank is provided, there is a second engine-mounted pump delivering the oil from the
engine’s sump into the tank.
The circulation lube oil is cooled in an tubular heat exchanger.
Installed in the full-flow oil pipe is a self-cleaning filter, and oil priming when starting the engine is ensured by
an electrically driven pump.
Chapter 2 - Page 2 0299 6464-0125 © 0201

2.9 Coolant system

The engine’s cooling water passes either through a tubular heat exchanger, a radiator or a cooling tower.
Engines runnung on MDF blend or HFO use a separate injector cooling circuit with compensation tank. A
heat exchanger is provided to dissipate the injector coolant heat to the engine’s cooling water. On the other
hand, the coolant can be heated up in this system.
The engine is started with compressed air sent into the cylinder head starting valve in the correct firing order
by one pilot air distributor on each engine side. An air cleaner is installed in the air pipe running to the distri-
butor.
The starting air master valve is fitted below the exhaust manifold at the engine’s free end. The starting air
pipe is an integral passage in the head with plug-in connections from head to head.
2.11 Monitoring system
Temperature and/or pressure switches can be provided for all engine operating media to effect alarms and/or
engine shutdown.
Thermostats are provided for oil, cooling water and charge air.
Furthermore, there is an overspeed protection and a crankcase oil mist detector.
Exhaust thermocouples are screwed into the cylinder heads.
2.12 Other components
All engines are equipped with a viscous-type torsional vibration damper, the direct-reversing models also
with a brake to slow down the engine before reversing manoeuvres.
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2.13 Engine assemblies and subassemblies
Assy. Group No. Description

01.1 Crankcase
01.2 Relief valve
02 Oil sump
04 Cylinder liner
05.1 Crankshaft
05.2 Flywheel
06 Connecting rod
07 Piston
08 Cylinder head with inlet and exhaust valves

09.1 Timing gear train
09.2 Auxiliary drive
10.1 Camshaft
10.2 Reversing mechanism
11 Inlet / Exhaust valve drive
14.1 Pump drive
14.2 Oil pump

16 Oil piping
17 Fuel injection pump
19 Fuel injector
22 Air intake cleaner
27 Speed governor
30 Starting pilot air distributor
31.1 Starting valve
31.2 Indicator valve
34 Vibration damper
38 Water piping
41 Exhaust manifold
43 Turbocharger
58 Charge air cooler
87 Air intake manifold
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2.14 Longitudinal section through engine

(In-line engine shown)
83000_0
© 0201 0299 6464-0125 Chapter 2 - Page 5

2.15 Cross section through engine

In-line engine
83001_0
Chapter 2 - Page 6 0299 6464-0125 © 0201

V-type engine
83404_0
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Chapter 2 - Page 8 0299 6464-0125 © 0201

R/S/BVM 640 Technical Data
3 Technical data
3.1 Model designation: R/S/BV 6/8/12/16 M 640
R Marine (direct-reversing)
S Marine (uni-directional)
B Turbocharged
V 4-stroke
6/8/12/15 6, 8, 12 or 16 cylinder
M Water-cooled
6 Generation No.
40 Piston stroke in cm
3.2 Designation of engine ends and sides and related definitions

The following definitions are to be understood with the viewer facing the engine’s main driving (flywheel)
end.
Driving end End which the viewer is facing
Free end Far end to driving end
LH side Side left of viewer
RH side Side right of viewer
Numbering of cylinders Starts from driving end (see drawings below)
LH engine Engine with manifold left of viewer (6 and 8-cyl. model)
RH engine Engine with manifold right of viewer (6 and 8-cyl. model)
Direction of rotation Engine can be supplied for clockwise (CL) and counterclockwise (CCL)
rotation.
6- and 8-cyl. model
83377_0
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Technical Data R/S/BVM 640
12- and 16-cyl. model
83376_0
Chapter 3 - Page 2 0299 6465-0125 © 0201

3.3 Basic data
Power and speed see acceptance documents

Bore 370 mm
stroke 400 mm
Capacity per cylinder 43.1 litres

total capacity:
6-cylinder 258.06 litres
Compression ratio 12:1
3.3.1 Design data
Cylinder head
Safety valve opens at 190 +- 5 bar
Drive mechanism
Crankshaft
Journal diameter 340 mm
Bearing shells: running width 106 mm
material steel/lead-tin-bronze/lead-tin
Piston
Material:
top heat-treated steel with hardened grooves
base forged light-alloy
Piston pin diameter 160 mm

No. of compression rings 4
No of oil control rings 1
Connecting rod
Rod length 810 mm
Big-end bearing material Same as for main bearings
Crankpin diameter 265 mm

Big-end bearing running width 103 mm
Small-end bush running width 179 mm / 93 mm
Crankcase
Crankcase, In-line engine Monobloc
Crankcase, V-type engine Monobloc, V-angle 48°
Cylinder spacing 570 mm
© 0201 0299 6465-0125 Chapter 3 - Page 3

Engine control
Firing order
6-cyl. model, clockwise rotation 1-4-2-6-3-5
6-cyl. model, counterclockwise rotation 1-5-3-6-2-4

8-cyl. model, clockwise rotation 1-3-2-5-8-6-7-4
8-cyl. model, counterclockwise rotation 1-4-7-6-8-5-2-3
12-cyl. model, clockwise rotation A1-B6-A3-B4-A5-B2-A6-B1-A4-B3-A2-B5
12-cyl. model, counterclockwise rotation A1-B5-A2-B3-A4-B1-A6-B2-A5-B4-A3-B6
16-cyl. model, clockwise rotation A1-B1-A3-B3-A2-B2-A5-B5-A8-B8-A6-B6-A7-B7-A4-B4
16-cyl. model, counterclockwise rotation A1-B4-A4-B7-A7-B6-A6-B8-A8-B5-A5-B2-A2-B3-A3-B1
Valve timing (in degrees crank angle)
Inlet valve opens (6, 8, 12, 16-cyl.) 44° b. TDC
Inlet valve closes (6, 8, 12, 16-cyl.) 23° a. BDC
Exhaust valve opens (6, 8, 12, 16-cyl.) 53° b. BDC
Exhaust valve closes (6, 12-cyl.) 42° a. TDC
Exhaust valve closes (8, 16-cyl.) 42° a. TDC
Starting valve opens (6, 8-cyl.) 8° b. TDC
Starting valve opens (12, 16-cyl.) 18° b. TDC
Starting valve closes (6, 8-cyl.) 46° b. BDC
Starting valve closes (12, 16-cyl.) 86° b. BDC
Governor
Mean piston speed 8 m/s at 600 rev/min

Idling speed 150 rev/min when standby oil pump is provided
250 rev/min when standby oil pump is not provided
Min. firing speed 80 rev/min
Exhaust gas system / Charging
Twin-circuit charge air cooler with LT-circuit and HT-circuit
Chapter 3 - Page 4 0299 6465-0125 © 0201

3.3.2 Operating data
Exhaust gas system / Charging
Charging system
Air temperature at engine inlet
50° - 60 °C depending on application
(= after charge air cooler)
Charge air temperature at idling and

70° - 75 °C
partial load (HFO-operation)
Max. adm. intake resistance 0.025 bar (250 mm of water)
Exhaust system
Exhaust temperature after turbine see acceptance documents
Max. adm. backpressure 0.025 bar (250 mm of water)
Permissible deviation from mean

see acceptance documents
temperature of all cylinders
Fuel system
Fuel grade see Chapter 6.3
Fuel consumption see acceptance documents
34 µm for diesel fuel or blended fuel oil,

Grade of filtration
37 µm for heavy fuel
Fuel pressure at pump inlet 4.0 + 0.5 bar
Fuel temperature at injection pump inlet see Chapter 6.3
Injection release pressure 350 bar
Type of injection nozzles see acceptance documents
Firing pressures see acceptance documents
Adm. deviation from mean indicated firing

see acceptance documents
pressure of all cylinders
6-cyl.: 1.8 m3/h

8-cyl.: 2.4 m3/h
Capacity required of separate lift pump
12-cyl.: 3.6 m3/h
16-cyl.: 4.8 m3/h
Plunger sealing oil consumption 0.1 g/kWh

Sealing oil pressure in pump 15 - 2 bar
Capacity of separate sealing oil pressure

up to 1 litre/h
pump
© 0201 0299 6465-0125 Chapter 3 - Page 5

Lube oil system

Oil grade see Chapter 6.2
Grade of oil filtration 34 µm for automatic filter
Oil temperature at engine inlet 55 +5 °C

Oil pressure after filter (rated speed and
4.4 - 5.1 bar
engine hot)
Min. oil pressure after filter at low idling

0.8 bar
speed
Oil priming pressure, regular serve

0.8 bar
(maintained for 1 minute!)
Oil priming pressure for standby engines
(automatics: every 1 minute for 10 0.8 bar
minutes)
Priming oil rate 6/8-cyl. model:
40°C oil temperature 300 litres/min
Priming oil rate 12/16-cyl. model:

Circulatin oil rate (Capacity of oil tank) 0.95 - 1.35 litres/kW
6-cyl.: 3.4 kg/h

8-cyl.: 4.5 kg/h
Total oil consumption
12-cyl.: 6.8 kg/h
16-cyl.: 9.0 kg/h
Min. oil circulation for standby engines 0.55 litres/kW
6-cyl.: 65 m3/h
8-cyl.: 78 m3/h
Separate standby oil pump, capacity
12-cyl.: 119 m3/h
16-cyl.: 150 m3/h
pressure depending on location of tank in system
Chapter 3 - Page 6 0299 6465-0125 © 0201

Coolant system
Grade of coolant see Chapter 6.4

6-cyl.: 600 litres
8-cyl.: 800 litres
Engine coolant capacity
12-cyl.: 1,200 litres
16-cyl.: 1,600 litres
Max. temperature after cylinder head 85°C
Required coolant pressure at engine inlet (full load) 3 to 4 bar

Pressure loss in engine, min. 0.8 bar
Engine inlet/outlet at full load 6 - 8°C
50 - 60°C for distillate fuel

Preheating temperature for standby engines
≥ 65°C for heavy fuel pier-to-pier
56°C for distillate fuel

Max. temperature at low temperature circuit of charge air cooler
51°C for heavy fuel
Max. raw water temperature at heat exchanger inlet 32°C
Temperature at injector inlet 90°C approx.
Compressed air system
according to Classification
Capacity of air receiver
Societies (min. 500 litres)
Starting/Reversing pressure,
max./min. see acceptance documents
3.3.3 Setting data for engine safety switches

Settings see list of measuring points supplied with the engine.
© 0201 0299 6465-0125 Chapter 3 - Page 7

3.4 Net weight of main engine components
Item Description 6-cyl. 8-cyl. 12-cyl. 16-cyl.

No. model model model model
approx. kg approx. kg approx. kg approx. kg
1 Engine w/o flywheel 29,000 37,000 48,000 60,000

2 Crankcase c/w bearing caps 11,000 13,500 15,000 20,000
3 Oil sump 1,200 1,425 1,200 1,425
4 Crankshaft 4,000 4,900 4,100 5,400

5 Cylinder liner 260 260 260 260
6 Connecting rod 155 155 155 155
Bearing shells:
7 big-end bearing 3.3 3.3 3.3 3.3
main bearing 4.7 4.7 4.7 4.7
8 Piston 140 140 140 140

9 Piston pin 40 40 40 40
10 Cylinder c/w valves 590 590 590 590
11 Inlet valve, exhaust valve 3 3 3 3
12 Exhaust valve cage c/w 29 29 29 29
13 Camshaft piece 70 70 70 70
14 Fuel injection pump 27 27 27 27
15 Fuel injector 6.7 6.7 6.7 6.7
16 Lube oil pump 210 210 210 210
17 Charge air cooler (fresh water) 650 650 650 650
Turbocharger: VTR 321 800 - 800 -

VTR 401 - 1,330 - 1,330
18
VTR 304 820 - 820 -
VTR - 1,800 - 1,800
19 Torsional vibration damper 200 290 755 755
20 Pump chest 450 450 450 450
21 Pump driving gear 70 70 70 70
Chapter 3 - Page 8 0299 6465-0125 © 0201

3.5 Tightening specification for heavy-duty bolts (Screws and nuts)

3.5.1 Tightening schedule (Procedure see 3.5.2)
Ass. Oil
Joints tightened by hydraulic
Item Gro Thread pressure Remarks reference
tool
up bar
Using 180 mm dia.tool, tighten

two internal nuts (1080 bar)
Crankcase/ Main bearing cap 1080/
1 01 M52x3 and then two external nuts
(vertical bolts) 1020
(1020 bar)
Job Card 02.16.03
2 08 Crankcase/Cylinder head M30x20 135 mm tool see Job Card 01.08.01
3 06 Conrod shank/ Big-end cap M33x2 135 mm tool see Job Card 02.06.01
135 mm tool
4 01 Crankcase/Foundation M42x3 1020
Job Card 03.07.01
Crankshaft/Balance weight 180 mm dia.tool for studs with

5 05 M42x3 700
(12/16-cyl.models) grooved nuts
© 0201 0299 6465-0125 Chapter 3 - Page 9

Ass. Preload Tighten

Remarks
Item Gro Joints tightened by wrench Thread torque angle
Reference
up Nm deg.
Tighten first
Crankcase/Main bearing cap vertical bolts
6 01 M39x3 240 90
(horizontal bolts) (item 1) Job
02.08.01
7 05 Flywheel/Crankshaft M39x3 240 90 Job 04.09.01
Bolt length may

Flywheel (Turning wheel) /
8 05 M39x3 240 105 vary! Job Card
Crankshaft
04.09.02
9 05 Flywheel/Adapter flange M27x2 130 75 Job 04.09.01
Cylinder head/Retainer for Job 01.11.01/02

10 08 M20x2 30 180
injector + starting valve Job 07.07.01
Bearing cap/Idler gear
11 09 M22x1.5 70 135 Job 04.04.01
support
Camshaft bearing cap/

12 10 M16 40 135 Job 04.01.01
Crankcase
13 10 Reversing end plate/Shaft M20x1.5 40 90 Job 04.07.03
Driving gear/Crankshaft (free

14 34 M30x2 130 135 Job 12.01.01
engine end with PTO-shaft)
Driving gear/ Crankshaft

15 34 (free engine end with PTO- M30x2 130 220 Job 12.01.01
shaft
16 34 Vebration damper/Crankshaft M24x2 70 60 Job 12.01.01
*) Tighten nuts in
Exhaust valve cage/Cylinder
18 08 M20x2 70 270*) three stages, see
head
Job 01.05.03
Inlet rocker arm fulcrum/

19 11 M20x1.5 70 90 Job 01.02.02
Rocker chamber
Exhaust rocker arm fulcrum/

20 11 M16x1.5 70 90 Job 01.02.02
Rocker chamber
Chapter 3 - Page 10 0299 6465-0125 © 0201

Ass. Preload Tighten

Remarks
Item Gro Joints tightened by wrench Thread torque angle
Reference
up Nm deg.
Crankshaft/Balance weight
21 05 M33x2 240 180
(6/8-cyl.models)
Turbocharger bracket/ 16-cyl. model

22 43 Charge cooler bracket M16 240 with VTR 321
(12/16-cyl. models) turbocharger
Turbocharger bracket/
with VTR 401
23 43 Charge cooler bracket M16 160
turbocharger
(16-cyl. model)
Injection line/ Injection pump/

24 21 - 80+10 - Job 07.07.02
Injector
25 19 Inlet adapter of injector M18x1.5 150 - Job 07.09.01

Cylinder head bolt/
26 01 M30x2 160 - Job 01.09.01
Crankcase
27 19 Injection nozzle nut M38x1.5 250 - Job 07.09.01

Tighten cross-
wise in 5 stages
Fixation pump element/ of 30 Nm each,
Injection pump Fixation thread and bolt
28 17 M16x1.5 150 -
injection pump/ camshaft head underside
casing lubricated
07.02.01 and
07.04.01
with VTR 304
29 43 Charge cooler bracket M16x140 240 -
turbocharger
(12-cyl. models)
with VTR 304
30 43 Charge cooler bracket M16x70 190 -
turbocharger
(12-cyl. models)
31 29 Coupling governing linkage M10 70 - Job 05.04.02
32 58 Charge cooler/Air socket M12x62 85 - Job 06.04.01

Charge cooler/ Charge
33 58 M12 80 - Job 06.04.01
cooler bracket
© 0201 0299 6465-0125 Chapter 3 - Page 11

3.5.2 Tightening procedure

Proceed by applying lube oil or DEUTZ S2 compound (Chapter 3.6) to threads.
Phase 1: Screw the bolts (screws, nuts) in place
Phase 2: Preload the bolts (screws, nuts)
- Torques up to 30 Nm
Hold socket wrench with tommy bar, hands being close together and preload bolts evenly (alternately and
crosswise, where applicable).
When using a plain or box wrench, the thumb should touch the wrench.
- Torques above 30 Nm
Preload bolts by torque wrench to the torque tabulated (crosswise and in stages, where applicable).
If a standard tool must be used, see adjoining figure and table below with typical values.
83003_0
Preloading torque Nm Lever length mm Force N
30 500 60
40 500 80
70 1000 70
130 1000 130
X = Force
Y = Lever length
83004_1
Chapter 3 - Page 12 0299 6465-0125 © 0201

Phase 3: Tighten the bolts (screws, nuts)

Tighten bolts evenly to the tabulated angle (alternately and crosswise, where applicable). Use extension, if
necessary. Where several bolts are involved and the angle is greater than 60°, tighten in stages of max. 60°.
Important:
Do not simply back overtightened bolts, but release them completely and tighten again as specified.
Should necking of shank be found after several tightening procedures, renew bolt.
3.5.3 Information on the hydraulic tool for annular nuts
For equipment design, oil filling and bleeding procedures see Job Card No. 02.16.02, which also gives a list
of hydraulic oils recommended,
Equipment handling is described in Job Card Nos. 02.16.01 and 02.16.03.
© 0201 0299 6465-0125 Chapter 3 - Page 13

3.6 Sealing compounds, locking compounds, lubrication compounds,

heat conductor compounds
Designation Description Application Use Remarks Equivalent

Product
Sealing compounds:
Asbestos with
It-Ö Oilresistant 1.5 mm thick Lube oil, gas oil
bonding agent
Combustion
Asbestos Serpentine type 2 mm thick
gases
Water -20 to
Rubber (natural +110°C with
Gi DEUTZ 2b
or synthetic) anti-freeze and
anti-corrosive
Air, water, lube

DEUTZ DW 5 Paner 0.3 mm thick
oil, gas oil
Water up to
DEUTZ DW 20 Leather board 1.5 mm thick 65°C; Lube oil,
gas oil
Deva metal from

DEUTZ DW 30 Gasket Exhaust system
Deventer
Reinz 4402 or
Asbestos w.
DEUTZ DW 40 Gasket Exhaust piping Ferrolastic from
artif. resin
Diring
Silastik 03-3305,
Tough-elastic black, from
Aminehardening Silicone India
DEUTZ DW 47 engine frame DOW-
compound rubber
joints CORNING,
Düsseldorf
Silastik 732 RTV

from DOW-
CORNING,
Silicone Tough-elastic Brussels and
DEUTZ DW 48 Compound
vulcanisate joints Terostat 33,
black, from
Teroson GmbH,
Heidelberg
Compound No.
54 from
DEUTZ DW 49 Compound Core hole plugs Fire risk
Sonderhoff,
Cologne
Curil or Teroson
DEUTZ DW 50 Compound Liquid seal Pump cases etc. Fire risk
fluid
Compound
Sigma from
DEUTZ DW 51 Compound Liquid seal Fire risk
Sonderhaff,
Cologne
Sealing surface Fa. Marston

Hylomar High-viscosity crankcase oilpan Ölchemie
Compound
SQ 32/H paste timing chest, GmbH, 5352
pump cases Zülpich
Necked-down
Wacker Chemie,
Silicone rubber Compound High-viscosity stud. f. Cyl.-
München
Head
Chapter 3 - Page 14 0299 6465-0125 © 0201


Product
Locking compounds:
Treads up to
Low-viscosity
M10, bearings
DEUTZ DW 55 agent becoming Loctite 601
bushes gears,
very tight
pins etc.
High-viscosity Threads from

DEUTZ DW 56 agent becoming M10, esp. studs, Loctite AVX
very tight surfaces
Liquid single-
component Low-viscosity Threads up to
DEUTZ DW 57 plastics harding agent easily M14 (adjusting Loctite 221
on metal under removable screws)
air exclusion
Medium-
viscosity agent Threads and
DEUTZ DW 59 Loctite 270
becoming very surfaces
tight
High-viscosity Threads and

DEUTZ DW 60 agent becoming faces hydr. and Loctite CVX
medium-tight pneum.
Only with DW 56
and DW 60 for
DEUTZ DW 61 Activator non-metallic and Non-corrosive Locquic T
surface treated
components
Lubricating compounds:
Prvention of
Never Seez from
Compound or thread seizure
DEUTZ S1 Heat-resistant P.H. Weidling &
spray (e.g. exhaust
Sohn KG
system)
Hydraulic
Special Sliding system sliding Molycote G-n
DEUTZ S2
compound Compound seals, waited rapid
bolts/studs
Reduces/
prevents friction Initially Clean
DOW-
and resultat com-w. per- or or
CORNING, 4000
corrosion of trichloretylene
DEUTZ S4 Molybdic sulfide Compound Düsseldorf or
tight-fit Apply compound
Van Laar, 4030
component. For very „thin“: some
Ratingen
temperatures - 0.005 mm.
40°C to +450°C
Electronic
insulating
Synthetic Molykote special
compound for
DEUTZ F2 silicone compound G-n
plug/socket
compound rapid
connections in
ignition systems
Multi-purpose
Acid-free grease for all
DEUTZ F5
lubricant bearings, -30°C
to +120°C
Extra-high-
Bearings,
pressure grease,
splines and
Molykote extremely
couplings for
Longterm 2 adhesive, good
temperatures -
corrosion
25°C to +110°C
inhibitor
© 0201 0299 6465-0125 Chapter 3 - Page 15


Product
Heat conductor compounds:

Conductor
compound: Heat compound
Temperature
DEUTZ P1 copper w. oil- from Stein &
switches
containing Sohn, Hamburg
bonding agent
General:
Necked-down
Fine Organics
Cleaning agent stud for
Liquid GmbH,
F0178 cylinderhead
Mannheim
mounting
Necked-down
Priming agent Liquid in spray- sutd for Wacker Chemie,
G790 bottle cylinderhead München
mounting
3.7 Dye checking of metal surfaces

See Job Card 00-03-02.
3.8 Use of liquid nitrogen
See Job Card 00-03-01
Chapter 3 - Page 16 0299 6465-0125 © 0201

R/S/BVM 640 Operation
4 Operating the engine
(See also Chapters 7, 8.2, 8.3 and “Summarized Instructions” hereto.)

4.1 Preparations for commissioning the engine
A Commissioning run-in engines following a brief idle period
B Commissioning engines following overhaul including
Replacements of pistons, cylinder liner or bearings
C Commissioning new engines or run-in engines following a prolonged idle period
4.1.1 Preparations for commissioning the engine on distillate fuel
Reference/
Item Job A B C
Job Card
Remove all preserving agent inside

1 Depreservation x Chapter 6.5
and outside of engine
Check inlet and exhaust valve

x x 01.01.01
clearance
2 Cylinder head
Check that inlet and exhaust valves
x
move freely in their guides
Inspect/tighten to the instructions

3 Foundation bolts x 03.07.01
of the building contractor
Change oil in hydraulic governor x 05.03.01
Inspect governing linkage x x 05.04.03

4 Governor Check oil level in hydraulic
x x 05.03.01
governor
Bleed hydraulic governor x 05.03.02
Check oil level in turbocharger x x 06.05.01

Exhaust gas system /
5 Inspect turbocharger x 06.06.01
Charging
Close drain valve in charge air pipe x x
Clean fuel service tank x
Top up fuel service tank x x
Clean fuel filter x x 07.10.01
Test fuel injectors x x 07.08.01

Check level in sealing oil tank x x
6 Fuel system
Drain water from fuel service tank x x x
Switch on sealing oil pump x x x

Open fuel service tank valve and
switch on fuel feed pump at 6 bar x x x
sealing oil pressure
Bleed fuel system x x 07.03.02
© 0100 0299 6466-0125 Chapter 4 - Page 1

Operation R/S/BVM 640
Reference/
Item Job A B C
Job Card
Top up lube oil tank x
Check level in lube oil tank x x x
Clean lube oil filter x x 08.09.02
Check level in oil reservoir for

7 Lube oil system x x 04.07.01
engine reversing mechanism
Fill up oil pumps x 08.04.01
Switch on priming pump and keep

0.8 bar pressure for min. x x x
10 minutes
Top up water level x
Check water level in header tank x x x
Bleed water system x x
Treat water with additives x x 09.01.01
Clean raw water filter x

8 Coolant system Open valves in all water pipework
x x
an check for correct valve positions
Switch on water preheater, if

provided, and heat water to min. x x
40 °C
Standby sets: Check that

preheating temperature is 50 - x x x
60 °C
Check that master valve and 01.11.01

x x
starting valves move freely 10.03.11
Clean air cleaner upstream of

x 10.02.02
starting pilot air distributor
Compressed air
9 Clean running-in screen upstream
system
of master valve. If removed, renew. x 10.03.91
(new engines)
Drain water from air receivers x x x 10.01.01

Check pressure in air receivers x x x 10.01.01
Separate Pumps: check pressures/

Engine protective temperatures in operating media x x x
10 (fuel etc.)
system
Test audible and visual alarms x x x
Drain condensate from pressure

11 Control units x x x 10.06.01
reducing station
Chapter 4 - Page 2 0299 6466-0125 © 0100

4.1.2 Preparations for commissioning the engine on heavy fuel or blended fuel
Reference/
Item Job A B C
Job Card
Remove all preserving agent inside

1 Depreservation x Chapter 6.5
and outside of engine
Check inlet and exhaust valve

x x 01.01.01
clearance
2 Cylinder head
Check that inlet and exhaust valves
x
move freely in their guides
Inspect/tighten to the instructions

3 Foundation bolts x 03.07.01
of the building contractor
Inspect governing linkage x x 05.04.03

Check oil level in hydraulic
4 Governor x x 05.03.01
governor
Bleed hydraulic governor x 05.03.02
Check oil level in turbocharger x x 06.05.01

Exhaust gas system /
5 Inspect turbocharger x 06.06.01
Charging
Close drain valve in charge air pipe x x
Clean fuel service tank x
Top up fuel service tank x x
Clean fuel filter x x 07.10.01
Test fuel injectors x x 07.08.01
Check level in sealing oil tank x x
Preheat fuel service tank x x x
Heat fuel filter - only the chamber

which is in use (if engine was shut x x x
6 Fuel system down while using heavy oil fuel). Chapter 6.3
Switch on viscosity control
x x x
equipment
Switch on sealing oil pump x x x
Drain fuel services tank x x x

Switch on fuel feed pump as 6+2
bar sealing oil pressure has been x x x
obtained
Bleed fuel system x x 07.03.02
© 0100 0299 6466-0125 Chapter 4 - Page 3

Reference/
Job A B C
Job Card
Top up lube tank x
Check level in lube oil tank x x x
Clean lube oil filter x x 08.09.02
Check level in oil reservoir for

7 Lube oil system x x 04.07.01
engine reversing mechanism
Fill up oil pumps x 08.04.01

Switch on priming pump and keep
0.8 bar pressure for min. x x x
10 minutes
Top up water level x
Check water level in header tank x x x
Bleed water system x x
Treat water with additives x x 09.01.01
Clean raw water filter x
Open valves in all water pipework

8 Coolant system and check for correct valve x x
positions
Switch on water preheater, if

provided, and heat water to min. x x
40 °C
Switch on injection valve water

x x x Chapter 6.3
preheater, if provided
Switch on injection valve preheater x x x
Check that master valve and

x x 10.03.11
starting valves move freely
Clean air cleaner upstream of

x 10.02.03
starting pilot air distributor
Compressed air
9
system Clean running-in screen upstream
x 10.03.91
of master valve (new engines)
Drain water from air receivers x x x 10.01.01
Check pressure in air receivers x x x 10.01.01

Separate pumps: check pressures/
Engine protective temperatures in operating media x x x
10 (Fuel etc.)
system
Test audible and visual alarms x x x
Drain condensate from pressure

11 Control units x x x 10.06.01
reducing station
Chapter 4 - Page 4 0299 6466-0125 © 0100

4.2 Commissioning and reversing the engine (Reversing: R/BVM models)

4.2.1 Commissioning
4.2.1.1 Running the engine on distillate fuel
Reference/
Item Starting the engine A B C
Job Card
1 Open indicator valves x x x

Turn engine over twice by barring gear. (but one hour after pr-
2 x x
lubricating engine at the latest.)
3 Place speed control in lowest possible position. x x Chapter 3.3.1

4 Keep assistant ready at the emergency shutdown lever. x x 05.00.01
With air receivers closed, move engine control lever from

“Stop” to “Start” position. Slowly open air shut-off valves
5 and - with indicator valves opened - briefly turn engine over. x x x
Close air receiver. Move control lever back to “Stop”
position.
6 Close indicator valves. x x x
7 Open air receivers fully.
Move control lever from “Stop” to “Start” position and - when

8 x x x Chapter 3.3.1
firing speed is attained - move on to “Run” position
Should engine fail to fire at the end of some three seconds,

9 repeat starting attempt. If several such starting attempts are x x x Chapter 7
unsuccessful, trace cause of trouble and remedy.
Switch off the preheater, if provided. (at ambient

temperature)
11 Switch on separate rew- and water pump. x x x
12 Raise engine speed slowly. x x x Chapter 4.7
13 Once full speed is attained, switch off oil priming pump. x x x

14 Once working temperature is reached, put engine on load. x x x Chapter 3.3.2
Note
Items 5 and 8 refer to the engine control units fully described in a separate manual. (The built-on control
uses no lever but a button for starting.)
Reversing the engine see Chapter 4.2.3
© 0100 0299 6466-0125 Chapter 4 - Page 5

4.2.1.2 Running the engine on heavy fuel or blended fuel
Reference/
Item Starting the engine A B C
Job Card
1 Open indicator valves x x x
2 Turn engine over twice by barring gear. x x
3 Place speed control in lowest possible position. x x Chapter 3.3.1
4 Keep assistant ready at the emergency x x 05.00.01
With air receivers closed, move engine control lever from

“Stop” to “Start” position. Slowly open air shut-off valves
5 x x x
and - with indicator valves opened - briefly turn engine over.
Move control lever back to “Stop” position.
6 Open air receivers fully. x x x
7 Close indicator valves. x x x
8 Switch off the preheater, if provided. (at min. 45°C) x x x
9 Switch on separate raw- and water pump. x x x

Move control lever from “Stop” to “Start” position and - when
firing speed is attained - move on to “Run” position.
Should engine fail to fire at the end of some three seconds,

wait for a while and repeat starting attempt. If several such
11 x x x Chapter 7
starting attempts are unsuccessful, trace cause of trouble
and remedy.
12 Raise engine speed slowly. x x Chapter 4.7
13 Switch off separate preheated filter x x x
14 Switch off injector preheater (if provided) x x x
15 Once full speed is attained, switch off oil priming pump. x x x

16 Once working temperature is reached, put engine on load. x x x Chapter 3.3.2
Note
Items 5 and 10 refer to the engine control units fully described in a separate manual. (The built-on control
uses no lever but a button for starting.)
Reversing the engine see Chapter 4.2.3
Chapter 4 - Page 6 0299 6466-0125 © 0100

4.2.2 Reversing the engine

a) On running engine
Where the engine is not all-automatically reversed, proceed as follows:
-Place control lever in “Stop” position.
-Reduce engine speed down to 130-160 rpm by means of flywheel brake.
-Move control lever to new direction (Reverse/Start).
-When completed reversing manoeuvre is visually indicated, start engine as under 4.2.1, items 7 to
14.
Note
For more details see separate instructions for engine control units.
b) On stopped engine (case of emergency)
Air bottle filled to a pressure of 30 bar.
-Switch on oil-preheating appliances and prelubricating pump. Minimum oil pressure: 0.8 bar.
-Reversing
Note
Crank engine after every 3rd camshaft displacement using cranking device.
© 0100 0299 6466-0125 Chapter 4 - Page 7

4.2.3 Engine starting conditions

It is strongly recommendable to start the engine in preheated condition: min. 45 °C of coolant and lubricant
when starting with diesel fuel. In the case of heavy fuel oil, special instructions are applicable. Only then can
the engine be run up to speed and load immediately.
Should it prove impossible to preheat the engine, it should be made sure that ambient and coolant tempe-
ratures are min. 15 °C.
While the hot engine may idle at as low as 150/min, the cold engine needs 500/min for idling, whereupon
the engine should be run up quickly, preferably with a growing load. Never repeat “Cold starts” within short
intervals, or the proportion of unburnt fuel may rise unduly.
Consecutive idling periods of less than 10 minutes (e. g. when performing tuning work on the engine)
should be avoided even when the engine is preheated, since the exhaust piping will not be hot enough to
avoid condensation of unburnt hydrocarbons.
Where ambient temperatures are below 0 °C, the preheating temperature should be higher by 1 °C for each
degree below zero. For example, an ambient temperature of -10 °C requires a preheating temperature of
min. 55 °C. Also, because of the resultant higher firing pressures the engine should be run with no more
than 75% rated power.
Chapter 4 - Page 8 0299 6466-0125 © 0100

4.3 Attendance in service

Record readings right from the start, unless automatically printed where periodecally unattended service is
provided. See also Chapter 3.3 and Acceptance documents.
Reference/
Daily checks and servicing jobs Reading
Job Card
Listen to running noise
Check colour of exhaust Chapter 7
1 General Inspect entire for leaks, especially

external pipework
Compare engine operating data

with acceptance documents
Lube oil temperature at engine inlet 55 °C
Water temperature after cylinder

85 °C
head
Water temperature differential at

6 - 8 °C
engine inlet/outlet
Coolant temperature at injector
2 Temperatures 90 °C
inlet
Fuel temperature in injection pump Chapter 6.3
Charge air temperature at engine

50 °C
inlet (full load)
Exhaust temperature at turbine Acceptance

outlet documents
Lube oil pressure at filter outlet

4.4-5.1 bar
(engine hat, rated speed)
Sealing oil pressure in injection

15-2 bar
pumps
Chapter
Water pressure at engine inlet
3.3.2
3 Pressures
Fuel pressure at injection pump approx.
inlet 3.0+0.5 bar
Acceptance
Charge air cooler pressure
documents
Starting air pressure, max/min 30/9 bar
Raw water pressure
© 0100 0299 6466-0125 Chapter 4 - Page 9

Reference/
Daily checks and servicing jobs Reading
Job Card
Check oil level in hydraulic

4 Governor 05.03.01
governor
Inspect charge air pipe for

06.02.01
condensate
Clean turbocharger air side 06.12.01

Exhaust gas system/ Check exhaust mean temperatures
5 Acceptance
Charging (Differences between cylinders are
documents
irrelevant for power output) Check
Chapter 3
limit temperatures
Check oil level in turbocharger
Drain water from fuel tank
Check fuel level in service tank
6 Fuel system Check differential pressure of

07.10.01
duplex filter
Check fuel leakage from shielded

11.01.03
line, if provided
Check oil level in tank

7 Lube oil system
Check differential pressure of filter 08.09.02
Check coolant levels in tanks for

engine and injector. Inspect drain
8 Coolant system 01.05.03
holes for exhaust valve plus cage
for water and/or oil
Charge air receivers and drain

Compressed air 10.01.01
9 condensate after cool down
system
Clean dust collector 10.03.02
Engine protective
10 Clean crankcase oil mist detector 11.05.01
system
Chapter 4 - Page 10 0299 6466-0125 © 0100

4.4 Engine stoppage/layoff

4.4.1 Running the engine on distillate fuel
I Short period
II Prolonged period
III Period exceeding 3 months
Item Job I II III
To prevent heat accumulation, let engine idle for five minutes or so before shutting
1 it down from prolonged full-load service. Where separate oil and coolant pumps x x x
are provided, keep them going for five minutes following engine shutdown.
Stop engine. x x x
2
Open indicator valves. x x x
Switch off fuel feed pump and fuel plunger sealing oil pump. x x
Close shut-off valves of air receivers and fuel service tank. x x
3 When water temperature falls off, switch on separate water pump. x x
Close shut-off valve before and after water cooler. x x
Open condensate drain valve in charge air pipe. x x

When frost is imminent, switch on water prheater, unless an anti-freeze has been
4 x x
added or drain water from entire cooling system.
Drain water from entire cooling system Drain all lubricating oil from engine and
x
attachments (except speed governor)
Preserve engine (Chapter 6.5) x

5
While the engine is out of service, switch on standby lube oil pump once a week
and turn engine over. (This applies only in the case of vibration of the shut-down x
engine, e.g. due to other engines in service.)
© 0100 0299 6466-0125 Chapter 4 - Page 11

4.4.2 Running the engine on heavy fuel or blended fuel

I Short period
II Prolonged period
III Period exceeding 3 months
Item Job I II III
1 Before stoppage it is advisable to run the engine with distillate fuel for min. 1 hour. x x
To prevent heat accumulation, let engine idle for five minutes or so before shutting
2 it down from prolonged full-load service. Where seperate oil and coolant pumps x x x
are provided, keep them going for five minutes following engine shutdown.
Stop engine. x x x
3
Open indicator valves. x x x
Switch off viscosity control, injector coolant pump, fuel feed pump and fuel
x x
plunger sealing oil pump
Switch off fuel feed pump and fuel plunger sealing oil pump. x x
4 Close shut-off valves of air receivers and fuel service tank. x x
When water temperature falls off, switch on separate water pump. x x
Close shut-off valve before and after water cooler. x x
Open condensate drain valve in charge air pipe. x x
When frost is imminent, switch on water preheater, unless an anti-freeze has been
5 x x
added or drain water from entire cooling system.
Drain water from entire cooling system. Drain all lubricating oil from engine and
x
attachments (except speed governor).
Preserve engine (Chapter 6.5) x

6
While the engine is out of service, switch on standby lube oil pump once a week
and turn engine over. (This applies only in the case of vibration of the shut-down x
engine. e.g. due to other engines in service.)
Chapter 4 - Page 12 0299 6466-0125 © 0100

4.5 Emergency operation

4.5.1 Operating the engine by means of emergency control
Should the engine control system (control desk or remote control) break down, starting and stopping
(RBVM: also reversing) can be effected manually at the engine itself, and the speed can also be adjusted at
the speed governor.
Note
It is necessary here to observe the preconditions stated in Chapters 4.1 to 4.4.
4.5.1.1 Starting the engine
Actuate lever 1 at the valve plate (see Fig. 1).
Should engine fail to fire after about 3 seconds, wait for a while and repeat starting attempt.
If several such starting attemps are unsuccessful, trace cause and remedy.
Fig. 1
83006_0
© 0100 0299 6466-0125 Chapter 4 - Page 13

4.5.1.2 Speed adjustment

The speed can be adjusted by turning the knurled screw 3 at the speed governor.
Read off the speed at indicator 4 (see Fig. 3).
Fig. 2 Fig. 3
83007_0 83008_0
4.5.1.3 Stopping the engine

The engine is stopped by pulling down the shut-down lever 4 in the direction “Stop” (see Fig. 4).
At the same time, the variable-pitch propeller is to be brought to the “0” position or the clutch, if provided,
is to be disengaged. After the engine has stopped, return the lever to the detent in the direction “Charge”.
83379_0
Chapter 4 - Page 14 0299 6466-0125 © 0100

4.5.1.4 Reversing the engine

1. Set speed at governor to idling (see Chapter 4.5.1.2).
Should the idling speed not fall down to 160 rpm, brake engine down to 130-160 rpm using flywheel
brake.
2. Actuate reversing lever 5 or 6 at pressure oil tank 7 (V-type engine: at cylinder banks A and B) (see
Fig. 5), according to the desired direction of rotation “Ahead” or “Astern” (see Figs. 6 and 7). The cams-
haft is now pushed in the chosen direction of rotation position. Wait until indicator 8 (V-type engine: at
cylinder banks A and B) is at the desired direction of rotation (“Ahead” or “Astern”) (see Figs. 8 and 9).
Fig. 5
Reversing
83010_0
© 0100 0299 6466-0125 Chapter 4 - Page 15

3. Restart engine (see Chapter 4.5.1.1).

4. Increase engine speed slowly by means of speed control (see Chapter 4.5.1.2).
Fig. 6 Fig. 7
Astern Ahead Ahead Astern
83011_0 83012_0
Fig. 8 Fig. 9
Astern Astern Ahead

Ahead
83013_0 83014_0
Chapter 4 - Page 16 0299 6466-0125 © 0100

4.6 Taking combustion indicator diagrams

Note
Be sure closely to observe the instructions issued by the indicator manufacturer, or readings are liable to be
incorrect.
The instrument recommended by us is the Maihak torsionspring indicator, type S, plunger 1/2, in the follo-
wing springs:
Max. combustion pressure Spring

100 bar F 100 bar No. 60
120 bar F 120 bar No. 70
160 bar F 160 bar No. 80
Pressures see acceptance records.

Taking indicator diagrams
Thoroughly blow through the indicator valves to prevent any carbon particles entering the gauge. Then
screw indicator firmly in ist place.
Put indicator paper on the recording drum and draw the zero line.
Open indicator valve and slowly turn drum for recording the combustion pressures. Record the entire curve
of the pressure as a function of the crank angle.
Remember that hand-drawn diagrams require a certain skill and experience. For assessment of the pres-
sure curve it is irrelevant whether the line comes from right or left.
For recording the compression pressure, cut out an injection pump element (Job 07.01.01) and check that
the control rod of the injection pump does not abut at ist load limit.
The following data should be entered upon the diagram:
Date, spring scale, cylinder No., corresponding exhaust temperature, control rod position, speed and
charge air pressure.
Assessing the readings
Compare readings with the values given in the Acceptance Record.
© 0100 0299 6466-0125 Chapter 4 - Page 17

4.7 Running in the engine

See Job Card 00.01.03.
Chapter 4 - Page 18 0299 6466-0125 © 0100

4.8 Running the engine with defective turbocharger

If blades of the turbocharger rotor are warped or broken (indicated primarily by turbocharger vibration or
abnormal noise) or if bearings have run hot, it will be recommendable to take the rubocharger out of service
(ABB instruct.). In this case it will be necessary to reduce engine speed/power substantially to make sure
that exhaust temperatures at full load as stated in the acceptance test sheet will not be exceeded. The
remaining b.m.e.p. will be 4.5 bar only.
This applies both to engines with a single turbocharger and engines with several turbochargers where not
all rotos have been inactivated.
The following table of maximum obtainable speeds/loads as a function of the b.m.e.p. of the rated full load
power refer to the most unfavourable case: marine engines using fixed-pitch propeller.
Max. obtainable speeds/outputs with inactivated turbocharger
B.m.e.p. of rated full-load power Obtainable speed in % of rated Obtainable power in % of rated
bar speed approx. power approx.
11 64 26
14 56.5 18
16 53 15
18 50 12.5
20 47.5 11.3
© 0100 0299 6466-0125 Chapter 4 - Page 19

Chapter 4 - Page 20 0299 6466-0125 © 0100

R/S/BVM 640 Systems
5 Engine media systems
5.1 Fuel system

F 16.2 Pipe collecting strip for pressure monitor
H 259 Steam supply on fuel filter
H 260 Steam discharge from fuel filter
H 375 Connection pressure monitoring
H 405 Overflow pipe from micro-filter/injection pump
H 407 Discharge from backleakageline inject.
H 410 Supply to micro-filter
H 414 Drain pipe for fuel system
H 417 Backleakge pipe from lagged injection pipes
H 418 Discharge from backleakage sump
K 10 Micro-filter, engine-mounted
K 11 Injection pump
K 14 Leak oil funnel
K 26 Leak oil pan (separator)
K 37 Flow monitor (double-walled injection lines)
K 50 Detector vessel (double-walled injection lines)
K 63 Pulsation damper
K 66 Injection valve
H 259/260... Only for pier-to-pier operation
H 414 ... Optional
H 417 ... If sheated injection lines
Legend for symbols see Chapter 5.7
© 0100 0299 6467-0125 Chapter 5 - Page 1

Systems R/S/BVM 640
5.1.2 Piping diagram for distillate fuel and blended fuel

6/8-cylinder:
83015_0
12/16-cylinder:
83380_0
Chapter 5 - Page 2 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.1.3 Piping diagram for heavy fuel, open system

6/8-cylinder:
83016_0
12/16-cylinder:
83381_0
© 0100 0299 6467-0125 Chapter 5 - Page 3

Systems R/S/BVM 640
5.1.4 Piping diagram for heavy fuel, closed system

6/8-cylinder:
83017_0
12/16-cylinder:
83382_0
Chapter 5 - Page 4 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.2 Lube oil system

H 601 Discharge from lower crankcase
H 604 Delivery pipe to suction pump
H 605 Suction pipe to delivery pump
H 608 Inlet in filter from separate cooler
H 609 Suction pipe to standby pump
H 630 Delivery pipe, delivery pump
H 634 Dirt oil discharge from micro-filter
S1 Storage tank
S2 Suction pump
S4 Pressure pump
S8 Filter
S 17 High pressure valve, by-pass valve
© 0100 0299 6467-0125 Chapter 5 - Page 5

Systems R/S/BVM 640
5.2.2 Low-level tank
83018_0
Chapter 5 - Page 6 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.2.3 High-level tank
83019_0
© 0100 0299 6467-0125 Chapter 5 - Page 7

Systems R/S/BVM 640
5.3 Coolant system

A4 Exhaust turbocharger
F 16.2 Pipe collection strip for pressure monitor
H 101 Suction pipe to raw water pump
H 102 Delivery pipe to raw water pump
H 117 Venting pipe (charge air cooler)
H 201 Suction pipe on cool, liquid pump HT
H 204 Supply to distribution pipe
H 206 Delivery pipe from standby cool, liquid pump HT
H 207 Discharge from cooling water or exhaust manifold
H 209 Venting pipe from engine
H 222 Breather pipe from charge air cooler LT
H 223 Supply to charge air cooler LT
H 224 Discharge from charge air cooler LT
H 228 Connection for venting pipe at exhaust turocharger
H 237 Breather pipe from charge air cooler HT
H 238 Discharge from charge air cooler HT
L2 Charge air cooler
R5 Raw water pump
U1 Cooling liquid manifold
U2 Centrifugal pump
U6 Cooling liquid distributer pipe
U 10 Transmitter
U 15 Temperature monitor
U 34 Check flap
Chapter 5 - Page 8 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.3.2 Coolant system without mounted pump

6/8-cylinder:
83020_0
12/16-cylinder:
83383_0
© 0100 0299 6467-0125 Chapter 5 - Page 9

Systems R/S/BVM 640
5.3.3 Coolant system with mounted pump

6/8-cylinder:
83021_0
12/16-cylinder:
83384_0
Chapter 5 - Page 10 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.3.4 Coolant system with mounted pump and second pump as raw-water pump
6/8-cylinder:
83022_0
12/16-cylinder:
83385_0
© 0100 0299 6467-0125 Chapter 5 - Page 11

Systems R/S/BVM 640

A7 Crankcase breathing system
D6 Starting valve
D8 Rotary starting air distributor
D 11 Contact pressure gauge (for wheelhouse)
D 55 High pressure air cleaner
D 56 Pressure reducing valve
D 61 Throttle check valve
F1 Control unit
F5 Governor
F 11 Measuring instrument board (and cubicle resp.)
F 16.1 Pipe collecting strip for pneumatics
F 34 Booster
H 302 Starting pipe
H 371 Connection pipe manifold for pneumatic system
H 702.1 Crankcase brathing
S 56 ... only if crankcase monitoring unit
D 56 only if crankcase monitoring unit
D 61 only if crankcase monitoring unit
Chapter 5 - Page 12 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.4.2 Pneumatic diagram (BVM)

6/8-cylinder:
83023_0
12/16-cylinder:
83386_0
© 0100 0299 6467-0125 Chapter 5 - Page 13

Systems R/S/BVM 640
5.4.3 Pneumatic diagram (SBVM)

6/8-cylinder:
83024_0
12/16-cylinder:
83387_0
Chapter 5 - Page 14 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.4.4 Pneumatic diagram (RBVM)

6/8-cylinder:
83025_0
12/16-cylinder:
83388_0
© 0100 0299 6467-0125 Chapter 5 - Page 15

Systems R/S/BVM 640
5.5 Injection pump plunger hydraulic seal

H 375 Connecting pressure monitoring
H 407 Discharge from backleakageline inject.
H 640 Pressure connection from seal oil pump
H 642 Overflow to high-level tank (seal oil)
K 11 Injection pump
K 66 Injection valve
S 17 High pressure valve, by-pass valve
S 28 Seal oil filter
Chapter 5 - Page 16 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.5.2 Fuel feed pump, separate valve seat lubrication

6/8-cylinder:
83026_0
12/16-cylinder:
83389_0
© 0100 0299 6467-0125 Chapter 5 - Page 17

Systems R/S/BVM 640
5.6 Injection nozzle cooling

H 414 Drain pipe for fuel system
H 504 Supply to injectors
H 505 Return flow from injectors
K 14 Leak oil funnel
Chapter 5 - Page 18 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.6.2 Injection nozzle cooling

6/8-cylinder:
83027_0
12/16-cylinder:
83390_0
© 0100 0299 6467-0125 Chapter 5 - Page 19

Systems R/S/BVM 640
5.7 Symbols used in piping diagrams (Definitions to DIN 30600)

5.7.1 Piping
DIN
30600
No.
Item Description Symbol Sheet Remarks
Serv.
No.
No.
Cooling water, lube oil,

2481
1.01 Principal media fuel oil, compressed
4.01
air
2481 Arrow above pipe or

1.02 Direction of flow
4.01 incorporated
2481
1.03 Raw water
4.01
1.04 Breather line
1.05 Exhaust manifold
1.06 Intake air line
1.07 2481 Control line e.g. on thermostat
e.g. protected
1.08 Double-walled line
injection line
1.09 Insulated pipe
24300
Sheet
1.10 Electric cable
4
2.1.5
2481
4.25 Intersection of two pipes w/o
1.11
2429 junction
1.7
2429 Intersection of two pipes

1.12
1.8 with junction
Chapter 5 - Page 20 0299 6467-0125 © 0100

R/S/BVM 640 Systems
DIN
30600
No.
Ser.
No.
No.
2429 Arrows point in

1.13 Pipe falling rising
4.12 direction of flow
1.14 2429 Ball compensator; joint
2429
1.15 4.1.1. Flexible joint Hose
5
2481
1.16 Drain tundish 582
4.32
2481 Pipe cross section reduction/

1.17 580
4.36 expansion piece
Outlet to atmosphere Tain

1.18 2481 583
cap
© 0100 0299 6467-0125 Chapter 5 - Page 21

Systems R/S/BVM 640
5.7.2 Shut-off fittings
DIN
30600
No.
Ser.
No.
No.
2481 Shut-off valve Throuhg-way

2.01 583
5.05 valve
2481
2.02 Angle valve 590
5.07
2481
2.03 Three-way valve 591
5.09
Dot at inlet end

2481 Non-return/through-way
2.06 604 indicates the non-
5.10 valve a) lockable
return (check) function
2481
2.07 Angled non-return valve 605
5.12
2481 Pressure reducing through- Larger cross section =

2.08 594
5.17 way valve lower pressure
2481 Angled pressure reducing

2.09 595
5.18 valve
2481
2.10 Floating-ball valve 578
5.15
2481
2.11 Gate valve 586
5.23
Chapter 5 - Page 22 0299 6467-0125 © 0100

R/S/BVM 640 Systems
DIN
30600
no.
Serv.
no.
No.
2481
2.12 Through-way cock 599
5.25
2481
2.13 Angled cock 600
5.26
2481 Three-way change-over

2.14 601
5.27 chock
2481
2.15 Four-way change-over cock 602
5.28
2.16
2481
2.17 Shut-off flap, not adjustable 607
5.29
e.g. throttle flap,

2481 Shut-off flap, infinitely
2.18 608 regulating flap,
5.30 adjustable
adjusting flap
2481
2.19 Non-return flap 606 Dot indicates inlet end
5.31
2429
Intake strainer with foot valve
2.20 3.2.2.
(flap)
1
2481
2.21 Drive by hand
5.34
© 0100 0299 6467-0125 Chapter 5 - Page 23

Systems R/S/BVM 640
DIN
30600
no.
Serv.
no.
No.
2.22
2481
Drive by motor M
5.35
2481
2.23 Drive by solenoid
5.36
2481 e.g. hydraulic or

2.24 Drive by fluid
5.37 pneumatic
2482
2.25 Drive by weight Quick-closing valve
5.40
2481
2.26 Relief valve, spring-loaded Angular design 2.02
5.42
2.27 Pressurestat
2481 Shows working

2.28 Shut-off element
5.58 conditionof system
2481
2.29 Shut-off element opened
5.59
2.30 Check valve
Chapter 5 - Page 24 0299 6467-0125 © 0100

R/S/BVM 640 Systems
DIN
30600
no.
Serv.
no.
No.
2481 Flow limiter using restrictor

2.31 612
5.65 plate (single orifice)
2481
2.32 Flow inspection glas 611
5.67
24300
2.34 page 3 Two-way valve
2.3
© 0100 0299 6467-0125 Chapter 5 - Page 25

Systems R/S/BVM 640
5.7.3 Accessories
DIN
30600
no.
Serv.
no.
No.
2481
3.01 Silencer 615
5.72
2481
5.79
3.02 Condensate trap 629
2429
5.2
2429
3.03 Separator
5.1
2429
3.04 Strainer
5.3
2429
3.05 Filter, single-element
5.4
3.06 Filter, twin-element
3.07 Filter, four-element
Back-flushing filter with

3.08 B: clean oil
treatment of flushing oil
Chapter 5 - Page 26 0299 6467-0125 © 0100

R/S/BVM 640 Systems
DIN
30600
no.
Serv.
no.
No.
3.09 Breather valve
3.10 Preheater for engine coolant Energy also 9.05
Energy also 9.05

Preheater for engine coolant
A: from oil reservoir
3.11 and lube oil I: engine coolant
B: to engine
II: lube oil
C: to oil reservoir
A: heavy oil inlet

3.12 Viscometer B: heavy oil outlet
Energy also 9.05
A: dirty oil inlet

B: clean oil outlet
3.13 Separator, manually cleaned C: water inlet
D: water outlet
E: sludge outlet
3.14 Separator, self-cleaning
© 0100 0299 6467-0125 Chapter 5 - Page 27

Systems R/S/BVM 640
DIN
30600
no.
Serv.
no.
No.
S: suction end
3.15 Sea box
D: delivery end
3.16 Over-/Underpressure valve
1219
3.17 Oiler
8.5.5
Filter
Filter with water separator
3.18 Water separator Automatic drainage
3.19 Heating
3.20 Heater
3.21 Viscometer T M
Chapter 5 - Page 28 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.7.4 Heat exchangers
DIN
30600
no.
Serv.
no.
No.
Zigzag pipe carries

Surface heat exchanger with
4.01 2481 heatabsorbing
media crossing
medium
5.7.5 Containers
DIN
30600
no.
Serv.
no.
No.
2481
5.01 Tank
10.02
2481
5.02 Tank with pipe coil
10.08
D A: from day tank

C B: to engine
5.03 Mixing tube C: from engine
D: breather pipe
B A E: drain
E
B A
43609 A: Charging pipe

5.04 3.3.3. Air receiver with valve head 732 B: Discharging pipe
3 E: Water drain
© 0100 0299 6467-0125 Chapter 5 - Page 29

Systems R/S/BVM 640
5.7.6 Machinery
5.7.6.1 Driving machines
DIN
30600
no.
Serv.
no.
No.
2481
6.01 Turbine 632 e.g. turbocharger
11.01
2481
6.02 Diesel engine 633
11.11
2481
6.03 Electric motor 635
11.14 M
6.04
6.05
5.7.6.2 Driven machines
DIN
30600
no.
Serv.
no.
No.
2481
6.06 Electric generator 636
11.47 G
2481
6.07 Centrifugal pump 708
11.22
2481
6.08 Reciprocating pump 697
11.23
Chapter 5 - Page 30 0299 6467-0125 © 0100

R/S/BVM 640 Systems
DIN
30600
no.
Serv.
no.
No.
2481
6.09 Gear-type pump 702
11.26
6.10 Hand-operated pump
2481
6.11 Rotary compressor 715 e.g. fan
11.33
2481
6.12 Reciprocating compressor 716 e.g. air compressor
11.34
2481
6.13 Turbocompressor 724 e.g.turbocharger
11.37
6.14
6.15
6.16
6.17
© 0100 0299 6467-0125 Chapter 5 - Page 31

Systems R/S/BVM 640
5.7.7 Water heat exchangers
DIN
30600
no.
Serv.
no.
No.
2481
7.01 Cooling tower 658
14.01
7.02
7 03
7.04
Chapter 5 - Page 32 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.7.8 Measuring and control
DIN
30600
no.
Serv.
no.
No.
Gauge shown alternately with or w/o circle
2481
8.01 Flow 687 Code letter F
15.01
8.02 2481 Level 776 Code letter L
2481
8.03 Pressure 681 Code letter P
15.04
2481
8.04 Temperature 688 Code letter T
15.03
© 0100 0299 6467-0125 Chapter 5 - Page 33

Systems R/S/BVM 640
DIN
30600
no.
Serv.
no.
No.
8.05 Service gauge
8.06
A:from engine
8.07 Thermostat (Flow divider) B:to pump
C:to cooler
A:Blended
temperature
8.08 Thermostat (Blender)
B:Hot
C:Cold
8.09
8.10
Chapter 5 - Page 34 0299 6467-0125 © 0100

R/S/BVM 640 Systems
5.7.9 Energies (shown in drawings only in horizontal position)
DIN
30600
no.
Serv.
no.
No.
2481
9.01 Mechanical energy 273
16.01
2481
9.02 Pneumatic energy 274
16.02
2481
9.03 Electric energy 278
16.06
2481
9.04 Hydraulic energy 279
16.07
2481
9.05 Heat energy 275
16.03
2481
9.06 Steam energy 276
16.04
9.07
9.08
© 0100 0299 6467-0125 Chapter 5 - Page 35

Systems R/S/BVM 640
Chapter 5 - Page 36 0299 6467-0125 © 0100

R/S/BVM 640 Expendables
6 Expendables
For full information on the expendables used in your engine please refer to our Technical Circulars which
are consistently kept up-to-date.
Technical Circulars currently in force are the following:
6.1 TR 0199-99-2082 concerning lube oils for ABB turbochargers

6.2 TR 0199-2090 concerning engine lube oil
6.3 TR 0199-99-2089 concerning fuel
6.4 TR 0199-99-2091 concerning engine coolant
6.5 TR 0199-99-2116 concerning engine conservation
© 0199 0299 6468-0125 Chapter 6 - Page 1

Expendables R/S/BVM 640
Chapter 6 - Page 2 0299 6468-0125 © 0199

R/S/BVM 640 Malfunctions
7 Operational malfunctions, and how to correct
7.1 Table of operational malfunctions
Operational malfunction Page
Engine fails to start 2

Engine fails to fire or stalls 3
Engine fails to develop full power

4-5
Engine knocks
Power/speed faliling off 5
Sluggish governor action
Excessive engine speed

6
Control lever unable to stop engine
Deficient oil pressure
Rising oil temperature
Heavy emission of oil mist from crankcase
Lube oil contaminated by water 7
Low turbocharging pressure

High turbocharging pressure
High charge air temperature
Air receiver pressure falling off
Starting air pipe getting hot 8
High engine coolant temperature
Engine fails to reverse
Poor combustion 9-10

Black exhaust
Blue exhaust 10
White exhaust
© 0199 0299 6469-0125 Chapter 7 - Page 1

Malfunctions R/S/BVM 640
7.2 General
Should trouble arise during engine starting or running, be sure to stop the engine immediately and to restart
the engine only after the fault has been remedied.
When opening crankcase, be sure to observe safety precautions (Job Card 02.00.01).
The listing below contains malfunctions which may occur if your equipment is not properly operated and
maintained. The listing is a summary of the faults most frequently occurring, and makes no claim to com-
pleteness.
7.3 Trouble Chart
Trouble Potential cause Remedy Chapter/Job Card

Low starting air Charge air receiver up
pressure to 30 bar
Incorrect valve
Adjust clearance 01.01.01
clearance *)
Leaky inlet or exhaust If necessary, regrind 01.07.01,

valves *) valves 01.07.03
Free valve with a blend
Inlet or exhaust valves of 50 % diesel fuel and 01.07.01,
binding *) 50 % lube oil; inspect 01.07.03
valve springs
Starting pilot air

distributor valve Recondition distributor 10.02.01
binding *)
Starting air master

Engine fails to start Recondition valve 10.03.11
valve binding
Master valve running in
screen not removed Remove screen 10.03.91
after 250 hours
Leaky starting or relief If necessary, regrind 01.11.01

valves or air piping *) valves; close pipe leaks 01.12.01
Oil pressure switch

defective or out of Check lube oil pressure
adjustment, so solenoid monitor; re-adjust or 11.01.02
valve preventing engine replace if necessary
start
Check safety device

Safety feature in
(bursting plate or safety
starting air pipe 11.01.02
valve) and repair if
defective
necessary
*) Caused by one or several cylinders
Chapter 7 - Page 2 0299 6469-0125 © 0199

Open fuel cock, switch

on fuel feed pump and
07.10.01
No fuel supply fill up service tank, If
07.03.02
necessary, clean piping
and filter and bleed
Inspect low pressure

Air in fuel piping piping for leaks; bleed 07.03.02
piping
Drain water from tank,

filter, pipng and clean. 07.10.01
Water in fuel tank
Fill in fresh fuel and 07.03.02
bleed system
Use better fuel, clean

Poor fuel quality Chapter 6.3
injection nozzles
Engine fails to fire or Injection pump not Replace any defective 07.01.01
stalls working properly pump element 07.02.02
Test injector 07.08.01

Inspect valve springs;
free valves. Check
01.07.03
No compression stems for eccentricity. If
01.07.03
necessary, regrind
valves
Remove piston and

Low compression 02.10.01
clean; replace rings
Injection pump control
05.04.03
rod or governor needle Free as required
05.02.01
binding
Inspect for defects like

Firing speed not
seizures of pistons or Chapter 3.3.1
reached
bearings
© 0199 0299 6469-0125 Chapter 7 - Page 3

Replace piston rings, if

Low compression 02.10.01
applicable
Inlet/exhaust valve 01.07.01
Regrind valve
leaky 01.07.03
Nozzles blocked by Clean nozzles or

07.08.01
carbon; needles seized replace
Injection pump element

Replace element 07.02.02
seized
Engine fails to develop Fuel feed pump

Replace pump
full power defective
Clean pressure charger,

06.12.01
air cleaner and cooler;
Low charge air pressure 06.03.11
eliminate air and
06.04.02
exhaust gas losses
Air in injection system Bleed system 07.03.02
Fuel reduction by
governor as a function
Have checked by Deutz
of engine speed, charge
pressure
Stop engine
immediately, remove 02.10.01
Piston defective or
piston and overhaul; 03.02.01
seized
inspect cylinder liner Chapter 4.7
Run in engine again
Stop engne; have

Bearing(s) seized crankshaft inspected
Engine knocks for cracks by Deutz
Excessive big-end Measure clearance 02.03.03

bearing clearance Replace bearing 02.05.01
High combustion Take indicator diagram, Chapter 4.6

pressure of all cylinders check injection timing 07.06.01
One cylinder
Check injection pump 07.01.01
overloaded
Chapter 7 - Page 4 0299 6469-0125 © 0199

Inspect thermodouple
11.01.05
Excessive exhaust and injector; examine
07.08.01
temperature of one exhaust valve. Have
01.07.03
cylinder injection pump adjusted
07.04.01
by Deutz
High combustion Match pressure to rest
07.06.01
pressure of one cylinder of cylinders
Engine overloaded Reduce load

Injector(s) not working
Engine is knocking, Test injectors 07.08.01
properly
hard running of engine
Clean pressure charger,
06.12.01
air cleaner and cooler;
Low charge air pressure 06.03.11
eliminate air and
06.04.01
exhaust gas losses
Turbocharger defective Overhaul charger 06.06.01
Foundation bolts loose Tighten bolts 03.07.01
High combustion
Check injection timing 07.06.01
pressure of all cylinders
Defective valve drive Recondition valve drive 04.02.01
Several cylinders fail to

See “Engine fails to fire” 3
fire
Poor combustion See “Poor combustion” 9-10
Piston or bearing
See “Engine knocks” 4-5
seizure
Engine overloaded Reduce load

Power/speed falling off
06.12.01
Clean turbocharger, air
Low/high charge air 06.13.01
cleaner and charge air
pressure 06.03.11
cooler
06.04.01
Have turbocharger
Turbocharger defective 06.06.01
overhauled
Fuel filter blocked Clean filter 07.10.01
© 0199 0299 6469-0125 Chapter 7 - Page 5

Governor/linkage not Inspect governor and

05.02.01
Sluggish governor working properly linkage
action Governor linkage
Free linkage 05.05.03
binding
Governing linkage 05.02.01

Excessive engine speed Free linkage or readjust
binding or maladjusted 05.04.03
Injection pump on/off Stop fuel supply and

Control lever unable to 05.00.01
control maladjusted or hence engine, and
stop engine 05.04.04
worn readjust on/off control
Low oil level in tank Top up oil 08.02.01
Oil too thin or diluted by

Renew oil 08.02.02
fuel
Oil filter blocked Clean filter 08.09.02
Oil piping leaky or

Remove leaks or clean
blocked
Oil pressure gauge

Replace gauge
defective
Deficient oil pressure Oil pump relief valve

Free valve 08.03.01
binding
Oil pump flap valves

Clean or replace valves 08.04.01
leaky
Recondition pump or
Oil pump worn 08.04.01
replace
Oil pressurestat dirty or

Clean or free valve 08.11.01
binding
Main/big-end bearing
Replace bearings(s) 02.03.03
clearance excessive
Chapter 7 - Page 6 0299 6469-0125 © 0199

Clean cooler
Rising oil temperature Oil cooler dirty
Inspect thermostat
Piston rings seized or Remove psitons;
Heavy emission of oil
defective; piston replace rings and/or 02.10.01
mist from crankcase
blowby overhaul piston
Crankcase, cylinder
head or exhaust valve Inspect parts
cage cracked
Liner jacket o-seals Remove liner; replace 03.04.01
defective o-seals 03.05.01
Lube oil contaminated
by water Subject cooler to
pressure test; if
Leaky oil cooler
necessary, eliminate
tube leak(s)
Oil separator works
Check separator setting
with additional water
ntake air cleaner or 06.03.11

Clean cleaner or cooler
charge air cooler dirty 06.04.01
If necessary, renew
Charge air pipe leaky 06.02.01
Low turbocharging gaskets
pressure Exhaust gas leaking
Inspect exhaust pipe
between engine and 06.01.01
and expansion joint
turbocharger
Pressure charger dirty Clean charger 06.12.01

Check injection timing, 07.06.01
High turbocharging Faulty combustion;
inspect exhaust valves; 01.07.03
pressure turbine dirty
clean turbine 06.13.01
© 0199 0299 6469-0125 Chapter 7 - Page 7

Charge air cooler dirty Clean cooler 06.04.01
Reduce load (over

High intake air 45°C: 5°C temperature
temperature rise = 2% reduction in
High charge air power)
temperature Check flow; clean filter,
Raw water flow
if necessary. Check
insufficient
charge air thermostat
High raw water
Reduce load
temperature
Air receiver pressure Leaky valves on air Clean valves, regrind

failing off receiver seats or renew cones
Starting air pipe getting Remove and regrind

Leaky starting valve 01.11.02
hot valves
Fill up with fresh water
Coolant quantity (evaporation losses) or
insufficient treated water (leakage
losses)
Raw water flow

If necessary, clean filter
High engine coolant insufficient
09.01.01
temperature
Thermostat not working
Inspect thermostat
properly
Air in system Bleed system
Cooler, valves or piping

Clean parts
blocked
Low oil level in

Top up as required 04.07.01
reversing mechanism
Reversing mechanism
Readjust as required 04.07.02
Engine fails to reverse out of adjustment
Reversing mechanism Recondition

04.07.03
defective mechanism
Leaky air piping Eliminate leaks
Chapter 7 - Page 8 0299 6469-0125 © 0199

The table below gives the possible causes and remedial action for three operational malfunctions:
black, blue and white exhaust gas coloration
Incomplete combustion Inspect injectors 07.08.01

Clean intake air cleaner,
06.03.11
turbocharger, charge air
06.12.01
Low charge air pressure cooler. Replace air
06.13.01
piping gaskets, if
06.04.02
necessary
Injectors defective Recondition injectors 07.09.01
Engine lugging Reduce load
Adjust valve clearance. 01.01.01

Inlet and exhaust valves
If necessary, regrind 01.07.01
Poor combustion, leaky
valves 01.07.03
black exhaust
Nozzles blocked Clean nozzles 07.08.01
Injection out of timing Retime injection 07.06.01
Low combustion/
Retime injection; check 07.06.01
compression pressure
combustion Kapitel 4.6
ratio
Change fuel; clean
Unsuitable fuel Kapitel 6.3
nozzles
Check injection timing 07.06.01

Engine overloaded
and governing linkage 05.04.04
(exhaust smoking)
setting Kapitel 4.6
Oil control rings sticking

Renew rings 02.10.01
or worn
Blue exhaust (lube oil in
Feed from oil reservoir
exhaust) Check oil level
insufficient
Heavy liner scoring Service liners 03.02.01
© 0199 0299 6469-0125 Chapter 7 - Page 9

Check heavy fuel

Kapitel 6.3
Fuel fails to fire temperature and
07.06.01
injection timing
Injectors defective Recondition injectors 07.09.01
Check temperatures of
Engine undercooled engine coolant, lube oil Kapitel 3.3.2
and charge air
White exhaust (fuel or Fuel contaminated by Change fuel; inspect Kapitel 6.3
water in exhaust) water injectors 07.08.01
Charge air cooler leaky Recondition cooler 06.04.01
Engine coolant leaking

into combustion
Insect parts, make
chambers (e.g. through
pressure tests and 01.08.01
cracks in cylinder head,
replace as necessary
liner, exhaust valve
cage)
Now power supply Check mains and fuse 11.05.02
Light intensity above

some 50 % of Clean windows in test
11.05.02
maximum value due to track
sensitivity control
Secondary alarm No propulsion air Check air supply
released by crankcase
oil mist detector. Light Open cover of
“Ready” goes out. No measuring unit e.g. due Close cover
signal “Main alarm”. to cleaning
Dirty air cleaner Clean or replace 11.05.02
Inspect cover gaskets

between measuring unit
Detector leaky
and mounting plate as
well as bellows.
Chapter 7 - Page 10 0299 6469-0125 © 0199

R/S/BVM 640 Maintenance
8 Maintenance schedules and Job Cards
8.1 Maintenance schedules

8.1.1 Initial maintenance jobs
Running
Job Job Card No. Foot note
hours
Valve rotator inspection 01.03.01 +
Cylinder head inspection 01.10.01
25 Lubricating system inspection 08.02.01

Lube oil filter cleaning 08.09.02
Crankcase oil mist detector servicing 11.05.02 +
Inlet/exhaust valve clearance checking 01.01.01
Crankweb deflection gauging 02.02.01
Foundation bolt inspection 03.07.01
Injection plunger sealing oil filter cleaning 07.03.05

50 Fuel duplex filter cleaning 07.10.01
Lube oil sampling 08.01.01
Inspection of cooling water with anti-corrosive oil Chapter 6 +
Starting air master valve screen cleaning 10.03.91
Cleaning filter of air pressure reducer (control console) 10.06.01 +
Lube oil changing turbocharger 06.05.01

100
Cylinder head round nuts retightened 01.09.01
Reversing oil level checking 04.07.01 +
Lube oil sampling 08.01.01

250 Inspection of cooling water with non-mineral oil additives Chapter 6 +
Raw water filter cleaning +
Starting air master valve screen final removal 10.03.91
Dust collector cleaning 10.03.02
500 Plug-type element cleaning automatic back flushing filter 08.09.02
1,000 Plug-type element cleaning automatic back flushing filter 08.09.02
+ Optional equipment
© 0301 0299 6470-0125 Chapter 8 - Page 1

Maintenance R/S/BVM 640
8.1.2 Daily checking and maintenance jobs

See Chapter 4.3
8.1.3 Periodic jobs
Item No. Job Card No. Foot Note
Interval: every 100 running hours:

1
Turbocharger turbine cleaning (Heavy fuel operation) 06.13.01 +

2
Crankcase oil mist detector servicing 11.05.02 +
Jobs as under Item 1

3
Cleaning fuel duplex filter 07.10.01
Cleaning filter of air pressure reducer (Control console) 10.06.01 +
Jobs as under Item 1

4 Valve rotator inspection 01.03.01 +
Injector coolant inspection Chapter 6 +
Interval: every 1,000 running hours:
Jobs as under Items 1 and 2
Engine control unit maintenance 05.01.01
Intake air cleaner cleaning (Turbocharger) 06.03.11 +
Turbocharger oil change 06.05.01

5
Inlet/exhaust valve clearance checking:
01.01.01 +
Operation with Heavy Fuel II ∆)
Injector inspection:
07.08.01 +
Operation with Heavy Fuel II ∆)
Dust collector cleaning 10.03.02
Crankcase oil mist detector checking 11.05.01 +
Chapter 8 - Page 2 0299 6470-0125 © 0301

Jobs as under Items 1 to 3
Cylinder head inspection 01.10.01
Crankweb deflection gauging 02.02.01
Injection plunger sealing oil filter cleaning 07.03.05
Filter cleaning (Valve seat lubrication) 07.03.05 +
Oil sampling 08.01.01
Temperature switch (oil, water, air) testing 11.01.01
6 Pressure switch (oil, water, air) testing 11.01.02
Injection flow switch testing 11.01.03 +
Exhaust gas thermocouple testing 11.01.05

Overspeed switch testing 11.03.01
Inlet/exhaust valve clearance checking: Operation with

01.01.01 +
Distillate, MDF Blend or Heavy Fuel I s)
Injector testing: Operating with MDF Blend or Heavy Fuel
07.08.01 +
I s)
Charge air water detector testing 11.06.01 +
Checking float switch 11.07.01 +
Motion parts inspection 02.01.01

Foundation bolts inspection 03.07.01
Reversing oil level inspection 04.07.01 +
Hydraulic governor oil change 05.03.01

7
Governor linkage inspection 05.04.03
Injection pump on/off control servicing 05.07.01
Injector testing: Operation with Distillate 07.08.01 +

Starting pilot air distributor air cleaner cleaning 10.02.02
Injector reconditioning: Operation with Heavy Fuel II ∆) 07.09.01 +
Exhaust valve servicing: Operation with Heavy Fuel II ∆) 01.07.03 +

Jobs as under Items 1 to 3 and 5

8
Injector reconditioning: Operation with MDF Blend or Heavy
07.09.01 +
Fuel I ∆)
© 0301 0299 6470-0125 Chapter 8 - Page 3

Charge air system inspection 06.02.01
Starting pilot air distributor inspection 10.02.01
Starting air master valve servicing 10.03.11
9 Lube oil filter automatic back flushing filter servicing 08.09.02
Turbocharger scavenging attachment servicing 06.13.02 +
Inspection valve seat lubrication 08.14.01
Exhaust valve servicing: Operation with MDF Blend or

01.07.03 +
Heavy Fuel I ∆)
Piston inspection: Operation with MDF Blend or Heavy Fuel

02.10.01 +
I or II ∆)
10 Jobs as under Items 1, 2 and 4 r
Servicing the turbocharge 06.06.01
11 Exhaust valve servicing: Operation with Distillate 01.07.03 +

Injector reconditioning: Operation with Distillate 07.09.01 +
Cylinder head servicing: Operation with Heavy Fuel II ∆) 01.08.01 +

Timing gear train inspection/gauging 04.08.01
Injection plunger hydraulic seal inspection 07.03.01

12 Main bearing inspection 02.04.01
Cylinder head servicing: Operation with Distillate or MDF

01.08.01 +
Blend or Heavy Fuel I ∆)
Piston inspection: Operation with Distillate 02.10.01 +
Piston servicing: Operation with Heavy Fuel II ∆) 02.10.01 +

13
Piston servicing: Operation with MDF Blend or Heavy Fuel
02.10.01 +
I ∆)
Chapter 8 - Page 4 0299 6470-0125 © 0301

Item No. Job Card no. Foot Note

14
by DEUTZ
Injection pump overhaul: Operation with Heavy Fuel II ∆) +
Service

Jobs as under Items 1 to 6, 8, 9 and 11
Inspecting camshaft bearings 04.01.01
Inspecting cylinder liners 03.03.01

15
Inspecting vibration damper 12.01.02
Piston servicing: Operation with Distillate 02.10.01 +
Injection pump overhaul: Operation with Distillate, MDF by DEUTZ

+
Blend or Heavy Fuel I ∆) Service Station
Intervals as required:
Cleaning intake air cleaner (Turbocharger) 06.03.11 +

Cleaning charge air cooler, air side 06.04.02
Cleaning lube oil filter 08.09.02
Cleaning charge air cooler, water side 06.04.01
Checking governor action 05.02.01
Oil change 08.02.02
Inspection of cooling water with non-mineral oil additives Chapter 6 +
Cleaning raw water filter

Reconditioning temperature switches (oil, water, air) 11.01.01
Servicing pressure switches (oil, water, air) 11.02.02
Reconditioning flow switch 11.01.03 +
Servicing flywheel or drum brake 12.05.01 +
© 0301 0299 6470-0125 Chapter 8 - Page 5

∆) Specification of Heavy Fuel according to CIMAC:

Heavy Fuel I to CIMAC 1, 3, 4 and 6
Heavy Fuel II to CIMAC 2, 5, 7 and 12
Specification: See Chapter 6
+ Optional equipment
Note
The inspection jobs listed in the Maintenance Schedule are to be carried out after the stated number of run-
ning hours; nevertheless, owing to the effected inspections, an extension or curtailment of the quoted
maintenance intervals may result, depending on the local operating conditions.
The Maintenance schedule comprises a summary of all inspection, maintenance and overhaul jobs, and also
refers to the Job Cards of Chapter 8 in the Instruction Manual.
Chapter 8 - Page 6 0299 6470-0125 © 0301

8.1.4 Instructions regarding periodic jobs to be carried out on engines running for up to 300 hours/
year
(DEUTZ minimun requirement)
Existing in addition are comprehensive national and international norms which may be employed, insofar as
they do not limit the instructions laid down here.
Item Jobs to be done in accordance with Engine Running Calendar Chapter

No. ready hours Interval or Job
for ope- Interval Card No.
ration every
1 Check fuel level in day tank
2 Check lube oil level
3 Check coolant level, exp. tank Chapter

yes daily
3.3.2
4 Check starting air pressure
Check engine and line systems for leaks
5
(operating media)
6 Drain water from compressed air receiver

yes weekly
7 Check/Empty leakage fuel tank
Prior to Trial Run:

8
Check oil level in hydr. speed governor
9 Check oil level in turbocharger
10 Trial Run (Section 9.2, KTA 3702.2)
2 hours’ trial run with max. possible

11
load (at least 50 %), during which:
Check operating data, pressures, tempera-

tures, etc. as per Acceptance Test Data
12 1. Check (and record) when steady-state has
been reached.
2. Check before engine shut-down. yes monthly
13 Check running noises
14 Check lube oil system (diff. pressure) 08.09.02
15 Check fuel system (diff. pressure) 07.10.01
Check warning system:
16 Pressure switches 11.01.02
Thermoswitches 11.01.01
17 Service compressor side of turbocharger 06.12.01
18 Check turbine side of turbocharger
© 0301 0299 6470-0125 Chapter 8 - Page 7


No. ready Hours Interval or Job
for Ope- Interval Card No.
ration every
19 Check lube oil 08.01.01
Chapter
20 Check composition of coolant half-
yes 150 6.4.3
yearly
21 Service lube oil filters 08.09.02
22 Service fuel filters 07.10.01
23 Change oil: Lube oil system 08.02.02
24 Hydr. speed governor 05.03.01
25 Turbocharger 06.05.01
26
27
28 Inspect crankcase, motion parts 02.01.01

29 Check foundation bolts 03.07.01
30 Check inlet/exhaust valve clearance 01.01.01

no 300 yearly
31
32 Check injectors 07.08.01
33 Service starting valves 01.11.01
34
Trial Run (Regulation KTA 3702.2)

2 hours’ trial rung (100 % load),
35
during which checks and maintenance work
as per items 12 to 18 are carried out.
Chapter 8 - Page 8 0299 6470-0125 © 0301


No. ready Hours Interval or Job
for Ope- Interval Card No.
ration every
36 Service cylinder head 01.08.01
37 Check big-end bearing 1 only per cyl. 02.04.01

38 Check piston bank 02.03.04
39 Check main bearings (2 only) 02.04.01
40 Check crankweb deflection 02.02.01
41 Inspect timing gear train 04.08.01
42 Check control rods 4-5 07.01.01

no 1500
43 Check starting pilot air distributor years 10.02.01
44 Inspect cams and rollers 04.01.02
45 Service starting air master valve 10.03.01
46 Check overspeed protection system 05.03.13
47 Service fuel feed pump 07.11.01
48 Renew pressure switches 11.01.02
49
50 Service turbocharger 06.06.01

7-8
51 Renew thermocouples (exh. temp.meas.syst.) no 3000 11.01.04
years
52 Renew thermoswitches 11.01.01
After expiry of this operating period, a DEUTZ specialist must be called in to determine the subsequent
maintenance schedule.
© 0301 0299 6470-0125 Chapter 8 - Page 9

In the case of emergency power sets, very high demands are made on dependability. In order to meet these
demands, the following precautions are necessary to rule out any „early breakdowns“ or other troubles:
● Commisioning is to be carried out by an engineer who has been specially trained by the engine manufac-
turer and who checks - and remedies, if necessary - the prelubrication system and the start automatics,
as well as (during operation) the indicating, warning and shut-down systems.
● The operating instructions issued by the engine manufacturer relating to coolant, fuel and lube oil are to
be strictly adhered to in oder to prevent breakdowns, e.g. due to corrosion, etc.
● The engines must be kept in good oder by observing the foregoing maintenance schedule, and must
undergo their scheduled test runs in accordance with the regulation KTA 3702.2.
● Uninterrupted idle-running periods may not exceed 24 hours.
Note
At the end of prolonged idling periods, run engine with min. 50 % load for min. 1 hour to remove all carbon
residues liable to have formed in the combustion chamber and exhaust system as well as on the valves.
Chapter 8 - Page 10 0299 6470-0125 © 0301

8.2 List of Job Cards
The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Mounting
Servicing
For maintenance intervals see Chapter 8.1
Group No.
00.00.00 General
00.01.03 Running-in instructions
00.03.01 Use of liquid nitrogen
00.03.02 Crack inspection with the diffusion liquid procedure
01.00.00 Cylinder head
11 01.01.01 Valve clearance checking ●
11 01.02.02 Rocker arm removal/refitment ●
11 01.02.03 Rocker arm inspection/reconditioning ● ●
08 01.03.01 Valve rotator testing ●

08 01.03.02 Valve rotator servicing/reconditioning (Rotocap) ● ●
08 01.03.03 Valve rotator servicing/reconditioning (DEUTZ) ● ●
08 01.04.01 Cylinder head removal ●
08 01.05.01 Inlet valve removal/refitment ●
08 01.05.02 Exhaust valve removal/refitment ●
08 01.05.03 Exhaust valve cage removal/refitment ●
08 01.05.04 Inlet and exhaust valves inspection ●
08 01.05.05 Valve spring removal/refitment ●
08 01.06.01 Valve guide inspection/reconditioning ● ●
08 01.07.01 Inlet and exhaust valve cones ● ●

08 01.07.02 Inlet valve seat insert removal/refitment ●
08 01.07.03 Inlet and exhaust valve seat rings ● ●
08 01.08.01 Cylinder head servicing ●
08 01.08.02 Cylinder head shut-off valve reconditioning ●
08 01.09.01 Cylinder head refitment ●
08 01.10.01 Cylinder head inspection ●

31 01.11.01 Starting valve inspection/testing ●
31 01.11.02 Starting valve servicing ●
31 01.12.01 Safety valve servicing ●
© 0301 0299 6470-0125 Chapter 8 - Page 11

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
02.00.00 Drive mechanism
05 02.00.01 Safety instructions for working on the drive mechanism

05 02.01.01 Drive mechanism inspection ●
05 02.02.01 Crankweb deflection gauging ●
06 02.03.01 Big-end bearing preload gauging ●
06 02.03.02 Bearing shell spread gauging ●
06 02.03.03 Bearing clearance gauging ●
02 02.04.01 Bearing shell (wear pattern) inspection ●
06 02.05.01 Big-end bearing removal ●
06 02.06.01 Big-end bearing refitment ●
01 02.07.01 Main bearing removal ●
01 02.08.01 Main bearing refitment ●

07 02.09.01 Piston removal, without scraper ring ●
07 02.09.01 Piston removal, with scraper ring ●
07 02.10.01 Piston inspection/servicing ● ●

07 02.10.02 Piston ring/groove gauging ●
07 02.10.04 Piston reconditioning ●
07 02.12.01 Piston pin removal/refitment ●

07 02.13.01 Piston pin bush gauging/reconditioning ● ●
07 02.14.01 Piston refitment, without scraper ring ●
07 02.14.01 Piston refitment, with scraper ring ●
Handling the 135-mm-diameter hydraulic clamping

49 02.16.01 ●
device
46 02.16.02 Hydraulic tool for annular nuts servicing ●
Handling the 180-mm-diameter hydraulic tool for annular

49 02.16.03 ●
nuts
05 02.17.01 Locating bearing removal/refitment ●
Chapter 8 - Page 12 0299 6470-0125 © 0301

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
03.00.00 Crankcase
01 03.01.01 Crankcase relief valve inspection/servicing ● ●

04 03.02.01 Cylinder liner (in situ) servicing ●
04 03.03.01 Cylinder liner inspection/gauging ●
04 03.04.01 Cylinder liner removal, without scraper ring ●
04 03.04.01 Cylinder liner removal, with scraper ring ●
04 03.04.02 Cylinder liner (removed) servicing ●
04 03.05.01 Cylinder liner refitment, without scraper ring ●
04 03.05.01 Cylinder liner refitment, with scraper ring ●
46 03.07.01 Foundation bolts inspection ●
09 03.09.01 Crankcase breather inspection ●
© 0301 0299 6470-0125 Chapter 8 - Page 13

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
04.00.00 Engine control
10 04.01.01 Camshaft bearing gauging/reconditioning ●

10 04.01.02 Camshaft locator inspection/reconditioning ● ●
11 04.02.01 Roller tappet reconditioning ●
09 04.04.01 Idler gears removal/refitment ●
10 04.05.01 Camshaft removal ●
10 04.05.02 Camshaft reconditioning ●
10 04.06.01 Camshaft refitment ●
10 04.06.02 Camshaft setting checking ●
10 04.07.01 Reversing oil reservoir inspection ●
10 04.07.02 Camshaft reversing assembly setting ●
10 04.07.03 Camshaft reversing assembly reconditioning ●

09 04.08.01 Timing gear train inspection/gauging ●
05 04.09.01 Flywheel removal/refitment ●
05 04.09.02 Flyring (Turning wheel) removal/refitment ●

05 04.11.01 Crankshaft gear removal ●
05 04.11.02 Crankshaft gear refitment ●
14 04.14.01 Pump chest removal/refitment ●

09 04.15.01 Auxiliary drive inspection/servicing ● ●
09 04.15.02 Auxiliary drive removal/refitment ●
Chapter 8 - Page 14 0299 6470-0125 © 0301

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
05.00.00 Governor
35 05.00.01 Safety precautions (Speed control system)

35 05.01.01 Engine control unit ●
27 05.02.01 Governor action checking ●
27 05.03.01 Hydraulic governor servicing ●
27 05.03.02 Hydraulic governor setting ●
27 05.03.04 Hydraulic governor servicing/reconditioning ● ●
27 05.04.01 Hydraulic governor removal/refitment ●
29 05.04.02 Governing linkage removal/refitment ●
29 05.04.03 Governing linkage inspection ●
29 05.04.04 Governor linkage setting ●
27 05.04.05 Injection pump stop arm (Load limit) setting ●

27 05.04.06 Hydraulic governor controls
56 05.07.01 Pneumatic injection pump fuel on/off control servicing ●
27 05.09.01 Starting pressure booster servicing/reconditioning ●
© 0301 0299 6470-0125 Chapter 8 - Page 15

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
06.00.00 Exhaust gas system / Charging
41 06.01.01 Exhaust manifold inspection/reconditioning ● ●

87 06.02.01 Charge air system inspection ● ●
87 06.03.11 Intake air cleaner (Plastics) servicing ●
58 06.04.01 Charge air cooler (twin-circuit), water side servicing ●
58 06.04.02 Charge air cooler, air side servicing ●
43 06.05.01 Turbocharger servicing ●
43 06.06.01 Turbocharger servicing/reconditioning ●
43 06.12.01 Turbocharger charger servicing ●
43 06.13.01 Turbocharger turbine servicing ●
43 06.13.02 Turbocharger scavenging attachment servicing ●
Chapter 8 - Page 16 0299 6470-0125 © 0301

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
07.00.00 Fuel system
Injection pump plunger control and locking mechanism,

17 07.01.01 ●
inspection
17 07.02.01 Injection pump element, removal/refitment ●
17 07.02.04 Injection pump-valve seat-sealing, reconditioning ●

17 07.03.01 Injection pump plunger hydraulic seal checking ●
17 07.03.02 Fuel system, servicing ●
21 07.03.04 Pulsation damper, checking ●

86 07.03.05 Lube oil filter, servicing ●
17 07.04.01 Fuel injection pump, removal/refitment ●
17 07.04.02 Injection locking device, removal/refitment ●
17 07.04.03 Injection pump drive, reconditioning ●
17 07.04.11 Fuel injection pump and connecting linkage, mounting
Geometrical commencement of delivery, setting and

17 07.06.01 ●
checking
19 07.07.01 Injector removal/refitment ●
21 07.07.02 Injection pipe dismounting/mounting ●
21 07.07.03 Injection pipe reconditioning ●

19 07.08.01 Injector inspection/testing ●
19 07.09.01 Injector reconditioning ●
20 07.10.01 Fuel duplex filter servicing ●
© 0301 0299 6470-0125 Chapter 8 - Page 17

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
08.00.00 Lube oil system
15 08.01.01 Lube oil sampling ●

15 08.02.01 Lube oil system inspection ●
15 08.02.02 Lube oil change ●
14 08.03.01 Lube oil pump relief valve servicing ●
14 08.04.01 Lube oil pump servicing ●
15 08.09.02 Automatic back-flushing filter ●
16 08.11.01 Lube oil pressurestat inspection ●
14 08.14.01 Valve seat lubrication ●
09.00.00 Coolant system
37 09.00.01 Coolant system draining
38 09.01.01 General notes on coolant treatment
10.00.00 Compressed air system
32 10.01.01 Compressed air system testing/servicing ●
30 10.02.01 Starting pilot air distributor testing/servicing ● ● ●
32 10.02.02 Starting pilot air distributor air cleaner servicing ●
32 10.03.02 Dust collector cleaning ●
32 10.03.11 Starting air master valve servicing ●

32 10.03.91 Starting air master valve running-in screen servicing ●
32 10.06.01 Pressure reducer station servicing ●
Chapter 8 - Page 18 0299 6470-0125 © 0301

The Job Cards cover

the following work:
Assy. Job Card
Inspection
Repairing
Servicing
Mounting
Group No.
11.00.00 Monitoring system
48 11.01.01 Temperature switch (oil, water, air) testing/reconditioning ● ●

Pressure switch (oil, water, air) inspection/testing/
48 11.01.02 ● ●
servicing
Warning device (Flow switch) for backleakage fuel

48 11.01.03 ●
(heatable), testing
48 11.01.04 Exhaust gas thermocouples removal/refitment ●
48 11.01.05 Exhaust gas thermocouples testing ●

48 11.03.01 Engine safety system Noris KN 923 ●
48 11.03.01 Engine safety system Noris KN 910 ●
48 11.03.01 Overspeed switch testing ●

48 11.05.01 Crankcase oil mist detector checking/servicing ● ●
48 11.06.01 Charge air water detector testing ●
48 11.07.01 Float switch checking ●
48 11.08.01 Main bearing overtemperature alarm ●

12.00.00 Other components
34 12.01.01 Viscous-type vibration damper removal/refitment ●
34 12.01.01 Geislinger torsional vibration damper removal/refitment ●

34 12.01.02 Geislinger torsional vibration damper ● ●
63 12.04.01 Drive coupling removal/refitment ●
63 12.04.02 Flywheel brake drum removal/refitment ●
85 12.05.01 Flyweel drum brake servicing ●
© 0301 0299 6470-0125 Chapter 8 - Page 19

8.3 Job Cards ordered by Maintenance Groups
Chapter 8 - Page 20 0299 6470-0125 © 0301

General
R/S/BVM 640 Job Card
00.01.03
Running-in instructions
The engines have been run in at the manufacturer’s

facility, so that no further running-in instructions are
really required. If maintenance work has been per-
formed at bearings, pistons, bushes, or if these
have been replaced, the engine has to be run in
again.
If available, run in the engine using running-in oil, If everything is all right:
which may remain inside the engine for up to ● Run the engine at low speed for 30 minutes.
50 operating hours.
● Check bearing and and crank compartments as
● Run the engine at low speed for 5 minutes. above.
● Shut down the engine, and check the bearing ● Run in the engine by gradually increasing RPM/
and crank compartments. load:
If any component is exhibiting serious
heat-up, find out the cause and eliminate
it.
Drive mode n = variable

Engine load determined mainly by the RPM
Running-in time Engine RPM %
in min. of rated RPM
60 35
30 45
60 55
15 35
45 70
15 55
45 80
In the case of propeller drives, may not be run
15 65
when the ship is moored!
45 90
15 70
45 95
© 0201 0299 6471-0125 JC 00 - Page 1

General
Job Card R/S/BVM 640
00.01.03
Drive mode n = constant

Engine load adjustable independently of the RPM
Running-in time Engine RPM in % Engine output in %
in min. of rated RPM of rated output
60 30 - 50 up to 5
30 50 5 - 10
60 100 up to 20
15 30 - 50 up to 5
45 100 30 - 40
15 100 up to 25
45 100 50 - 60
15 100 20 - 30
45 100 80 - 90 In the case of propeller
drives, may not be run
15 100 30 - 40 when the ship is moo-
45 100 80 - 90 red!
● Once you have finished the running-in program,

check the engine’s operating values, and com-
pare them with the acceptance test report. If you
find any significant divergences, ascertain the
cause.
During the following 24 operating hours,
the engine must not be run with fitted in-
jection pump blocking and reduced
speed, nor with overload.
You will reduce the stresses on your engine if you
make sure that load changes are not made with
abrupt transitions.
JC 00 - Page 2 0299 6471-0125 © 0201

General
00.03.01
Use of liquid nitrogen
Never touch liquid nitrogen and under-

cooled parts:
Risk of injury!
When placing the components into liquid

nitrogen, there may be “jumping” liquid
drops.
• Wear protective goggles and gloves.
• Wear closed-up clothing.
Care for sufficient ventilation!
For occasional work of short duration, place two

concentric containers into each other and fill the
clearance between the two containers with glass
wool, cork meal or sand.
Use a suitable tool for placing the components into
and taking them out of the container.
Pour the nitrogen from the containers, in which it is
delivered, into the special basin and then dip the
metal parts into this liquid. The start of the under-
cooling process is indicated by heavy “boiling”.
Bubbles will form until the metal parts have assu-
med the nitrogen temperature (-196 °C). Once no
more bubbles form, the parts are ready for installa-
tion.
Quantity of nitrogen needed
Under normal conditions, one kilogram of metal to
be cooled from +15 °C to -196 °C requires the follo-
wing quantity of liquid nitrogen:
● 0.60 l for steel
● 0.66 l for cast iron
● 0.45 l for bronze, copper, brass
● 0.96 l for aluminium
© 0201 0299 6471-0125 JC 00 - Page 3

General
00.03.01
JC 00 - Page 4 0299 6471-0125 © 0201

General
00.03.02
Crack inspection with the diffusion liquid procedure
Aids
- Cleaning agent (trichloroethylene)
- Diffusion liquid (red)
- Developer (white)
- Dry cloth
- Protective goggles
- Protective gloves
- Extractor device
When working with trichlorethylene: Appling the developer

Risk of poisoning! ● Use a spray gun or a brush to apply a thin film of
developer. (Avoid applying twice to the same
area).
Cleaning the components
● Allow the developer to dry for 1 - 2 minutes.
● Wear protective goggles and protective gloves!
Due to the “blotting paper” effect of the devel-
● Make sure the room is properly ventilated! oper, the diffusion liquid is sucked out of the
● Make sure the vapours are extracted. Never crack, and thus becomes visible, see Fig. 4.
inhale them!
● Use cleaning agent to degrease the component.
● Allow the cleaning agent to act for 10 - 15 minu-
tes.
● Rub down the surface you want to check with a
dry cloth. This will get rid of all the grease resi-
dues which might otherwise fill in and cover up
any cracks present, see Fig. 1.
Applying the diffusion liquid
● Apply diffusion liquid, see Fig. 2. Use a spray
can, a spray gun, or a brush to do this, or
immerse the component in the diffusion liquid.
● Allow the liquid to act for the time period speci-
fied by the manufacturer.
● Clean the component with water, until the diffu-
sion liquid has been washed off the surface, and
remains only in the cracks, see Fig. 3.
● Rub the surface thoroughly with a cloth to dry it.
● Allow the component to finish drying.
© 0201 0299 6471-0125 JC 00 - Page 5

General
00.03.02
Assessment
- It may happen that very thin cracks do not
become visible until several hours have passed.
- Due to the diffusion liquid being sucked upwards,
red points will form in the white developer coa-
ting wherever there are cracks or other surface
irregularities.
- Red lines indicate cracks.
- Red dots indicate pitting and porosity.
- A dotted red line will appear in the case of:
- very fine cracks,
- metal fatigue,
- an only partial rupture.
Fig. 1 Diffusion liquid procedure (25495_0)
JC 00 - Page 6 0299 6471-0125 © 0201

Cylinder head
01.01.01
Valve clearance checking
Tools
- Standard tools
- Feeler gauge
Aids
- DEUTZ DW 48 compound
Checking
Check inlet and exhaust valve clearance and adjust
as necessary.
Note
Excessive clearance causes the valves to open jer-
kily so the cams may be damaged; insufficient clea-
rance results in failure of the valves to close
completely, so they will be destroyed by the gases
streaming out.
Job
Open indicator valves of all cylinders. Release knob
screws (4) and remove rocker chamber cover (1).
Turn crankshaft so the respective piston is in com-
pression TDC and the tappet roller will rest on the
cam base circle.
Clearance “X” between valve stem (6) and socket
(5) should be 0.5 mm with engine cold and 0.7 mm
Fig. 1 Cylinder head (83133_0)
with engine hot.
If clearance is not correct, release locknut (3), insert
feeler gauge between stem (6) and socket (5) and
turn pressure screw (2) until gauge can only be
moved with a slight drag.
Retain screw (2) in this position and retighten lock-
nut (3). Recheck clearance. Before refitting cover
(1), check that gasket (7) is intact, otherwise remove
gasket. Clean sealing surface. Apply DEUTZ DW 48
compound to cover (1) and new gasket (7).
Close indicator valves.
© 0301 0299 6472-0125 JC 01 - Page 1

Cylinder head
01.01.01
JC 01 - Page 2 0299 6472-0125 © 0301

Cylinder head
01.02.02
Rocker arm removal/refitment
Tools
- Standard tools
- Feeler gauge
- Hydraulic expansion tool
Cross-references
- Job Card 02.16.01
Job Refitting the exhaust rocker arms

Turn camshaft so the tappet roller of the lower valve Slip arm (11) with chamfer ahead over spindle (16)
drive rests on the cam base circle and the rocker and place on cylinder head. Screw in bolt (12) and
arms are unloaded. screw (13). Tighten bolt (12) as per tighening
Removing the inlet rocker arms with lInk to ex- instructions. Screw nut (14) in place and tighten with
haust valve hydraulic tool (Job Card 02.16.01 and tightening
instructions). Connect oil line with banjo bolt (15).
Unscres banjo bolt (10). Release annular nut (6) by Gauge axial clearance.
hydraulic tool (Job Card 02.16.01). Remove nut.
Unscrew cheese-head screw (5) and waisted bolt
(3). Raise spindle (2) with rocker arms from cylinder
head. Unlock hex. bolts (9) and unscrew. Take down
stop washer (8). Withdraw link (7) and inlet rocker
arm (4) from spindle (2).
Removing the exhaust rocker arms
Unscrew banjo bolt (15). Release annular nut (14)
by hydraulic tool (Job Card 02.16.01).
Remove nut. Unscrew cheese-head screw (13) and
waisted bolt (12). Raise spindle (16) with exhaust
rocker arm (11) from cylinder head and withdraw
spindle.
Cleaning
Clean all rocker arm components. Blow through all
oil passages in arms and pressure screw and check
that passages are free.
Before refitment, apply oil to bushes and spindles. Fig. 1 Cylinder head(83134_0)
Clean arm seats on cylinder head.
© 0301 0299 6472-0125 JC 01 - Page 3

Cylinder head
01.02.02
Refitting the inlet rocker arms with link to exhau-

st valve
Position link (7) on shorter and inlet rocker arm (4)
on longer journal of spindle (2). Secure stop washer
(8) with hex. bolts (9). Lock bolts (9). Place arm on
cylinder head. Screw in cheesehead screw (5) and
waisted bolt (3). Tighten bolt (3) as per tighening
instructions. Screw nut (6) in place and tighten by
hydraulic tool (Job Card 02.16.01 and tighening
instructions).
Connect lube pipe (1) with banjo bolt (10) to rocker
fulcrum.
JC 01 - Page 4 0299 6472-0125 © 0301

Cylinder head
01.02.03
Rocker arm inspection/reconditioning
Tools
- Standard tools
- Feeler gauge or caliper rule
- Brass madrel
Aids
- DEUTZ DW 56 locking compound
Cross-references
- Job Card 01.02.02
Inspection Reconditioning
Measure rocker arm bearing clearance and replace When the wear limit has been reaced or other
bearing bushes, if required. defects have been discovered, replace the respec-
Job tive bush.
Remove rocker arms (Job Card 01.02.02). Clean all Inlet rocker (4) and exhaust rocker (7): remove stop
components. Use feeler gauge to measure radial rings (5) and drive out bush with a brass mandrel.
clearance between bush (2) and fulcrum (3). Check Inlet rocker (4) and exhaust rocker (12): introduce
whether most of the wear has ocurred at the bottom new bush with oil hole at top.
of bush (2) of inlet rocker (4), bush (10) of exhaust
rocker (7) and bush (11) of exhaust rocker (12).
Bush (8) of exhaust rocker (7) may also be worn at
a different point.
Bearing clearance:
New condition 0,030 - 0,090 mm
Wear limit 0,2 mm
Using sliding calipers, measure the inside diameter
“D” of bushes (2), (8), (10), (11) and the outside dia-
meter “d” of the associated journals.
Clearance = D - d
Check seats of pressure screws (1) and ball-end pin
(6) as well as stop ring (5) for defects and wear.
Renew as required.
Fig. 1 Rocker arm (83136_0)
© 0301 0299 6472-0125 JC 01 - Page 5

Cylinder head
01.02.03
Exhaust rocker (7): Install bush (8) so that its oil
bore coincides with the lube oil supply bore of the
rocker arm when pressed in and bush is flush with
the rokker arm.
Refit any removed plugs with DEUTZ DW 56 com-
pound.
Install bushes (2), (8) and (10) as shown in Figs. 1
and 2. Install bush (11) of exhaust rocker (12) to be
flush at “X”. For bush installation, clamp down arm
with bush in a vise and press home bush without
canting.
Proceed by driving in bush with the mandrel until oil
drillings mate. Fit stop rings (5) and lock. Install arm
on fulcrum (3) and check clearance.
JC 01 - Page 6 0299 6472-0125 © 0301

Cylinder head
01.03.01
Valve rotator testing
Tools
- Pocket lamp
Cross-references
- Job Card 01.03.02, 01.03.03, 01.05.02
Testing
Check inlet/exhaust valve rotator for correct fun-
tioning.
Job
Remove inspection hole cover from rocker chamber
cover and observe working of rotator (1) with the aid
of a pocket lamp. During the valve stroke there
should be a slight rotation of
a) clamping nut (item 2 in Job Card 01.05.02)
clockwise with the DEUTZ rotator (Job Card
01.03.03)
b) spring cap (item 1 in Job Card 01.05.02) coun-
ter-clockwise with the Rotocap rotator (Job Card
01.03.02)
Approximate valve rotation times on engines run-
ning at more than 500 rev/min:
- Exhaust valve with DEUTZ rotator:30 seconds Fig. 1 Valve rotator (83139_0)
- Exhaust valve with Rotocap rotator:90 seconds
- Inlet valve with Rotocap rotator:90 seconds
Longer periods will require an early overhaul of the
rotator.
Servicing and reconditioning of Rotocap rotators
see Job Card 01.03.02.
Servicing and reconditioning of DEUTZ rotators see
Job Card 01.03.03.
© 0301 0299 6472-0125 JC 01 - Page 7

Cylinder head
01.03.01
JC 01 - Page 8 0299 6472-0125 © 0301

Cylinder head
01.03.02
Valve rotator servicing/reconditioning (Rotocap)
Tools
- Standard tools
Cross-references
- Job Card 01.05.01, 01.05.05
Servicing
Dismantle rotator and service. If reconditioning is
required, see hereunder.
Job
After removing springs (1) (Job Card 01.05.05), take
down spring cap (3) and rotator (4) from valve guide
bush (2).
Remove cup spring (6) from base (9). Take out ball
(8) and springs (10).
Clean all components and inspect for wear.
When reassembling check that spring (10) is loca-
ted at the lowest point of the race of ball pocket (11)
and ball (8) at the highest point.
Oil pockets (11). Place cup spring (6) on base (9).
Important:
Cup spring (6) must rest on base (9) with its smaller
diameter.
When turned by hand, the rotator must offer no
appreciable resistance.
Fit rotator (4) and spring cap (3). Install springs (Job
Card 01.05.05).
Reconditioning
When cup spring (6) is defective, replace entire
rotator.
© 0301 0299 6472-0125 JC 01 - Page 9

Cylinder head
01.03.02
Fig. 1 Rotocap (83140_0)
JC 01 - Page 10 0299 6472-0125 © 0301

Cylinder head
01.03.03
Valve rotator servicing/reconditioning (DEUTZ)
(Valid only for exhaust valves) Tools

- Standard tools
- Torque wrench
- 100 g mallet
Aids
- DEUTZ DW 60 and DW 59 compounds
Cross-references
- Job Card 01.05.05
Servicing Reconditioning
Remove exhaust valve rotator and check that freew- Unscrew nuts (5) and dismantle freewheel unit.
heel unit works smootly. Service driver, roller and Clean all components. Replace clamping set com-
coulisse. If reconditioning is required, see hereun- prising clamp (2) and spring (3). When refitting, be
der. sure marks (12) of clamp (2) point inside (View X).
Job Reassemble unit. If stud (11) has been removed,
refit with DW 59 compound. Renew and tighten nuts
Checking the freewheel unit (5) through a torque of 6 Nm. Recheck freewheel
Remove rotator after removing springs (Job Card unit functioning before refitment.
01.05.05).
Link driver (8) to freewheel unit. Retain unit at spring
cap (4). With a 100 g mallet gently strike against
driver (8) in clockwise (locking) direction. Once
outer ring (1) springs back and - after several blows
- slowly turns in counter-clockwise (free) direction,
the freewheel unit can be kept in service. Otherwise,
recondition as described on page 2.
Servicing the Driver (8), Roller (9), and Coulisse
(14)
Should roller (9) fail to turn easily on its stud or pre-
sent bevels or other signs of wear, replace. Remove
all traces of old locking compound with a wire brush.
Before srewing hex. nuts (6) in place, clean stud
and nut thread with a grease solvant. When solvant
has completely volatilized, apply a thin film of DW
60 to the stud thread. After the first screw turn, add
some DW 60 into the nut thread facing. Tighten nut
(6) through about 25 Nm. Tighten both bolts (7)
securing the driver with some 15 Nm. Continue
using coulisse only if wear does not exceed slight
and smooth scoring. Replace coulisse, if noticeable
wear or pittings in the runway are present
© 0301 0299 6472-0125 JC 01 - Page 11

Cylinder head
01.03.03
Fig. 1 Valve rotator (50019_1)

A Marking groove
X View X
JC 01 - Page 12 0299 6472-0125 © 0301

Cylinder head
01.04.01
Cylinder head removal, In-line engine
Tools
- Standard tools
- Hoist
- Hydraulic tool for annular nuts
- 4 thread protectors
- Head suspension device
Cross-references
- Job Card 01.08.01, 01.09.01, 02.16.01,
06.02.01
Job
Unscrew plug or open cock on crankcase to drain
water down to head bottom edge. Remove rocker
chamber cover (16). Disconnect lines for fuel injec-
tion, starting control air, nozzle coolant, fuel back-
leakage and rocker arm lubrication.
Disconnect starting air pipe (11) on both sides of
cylinder head (8). To do this, unscrew bolts and
push sliding piece of starting air pipe (11) axially to
the right into the head. Charge air pipe (10) need
not be disconnected, provided spacers (9) are dis-
placed (Job Card 06.02.01).
Remove guard (4). Disconnect respective section of
water manifold (1) after releasing flanges. Remove
water outlet pipe (3) after unscrewing bolts at cylin-
der head (8). Disconnect inlet pipe (7) by uns-
crewing bolts (5).
Unscrew bolts (6) of exhaust manifold.
Release anular nuts (13) by hydraulic tool (Job Card
0216.01) and remove along with washers (12). Put
four thread protectors (22) on studs (17), choosing
every second stud for this purpose.
Fit suspension device (18).
Take care not to damage joint faces, studs or
pushrod cover tubes. Put down head (8) on a woo-
den support.
Cylinder head servicing see Job Card 01.08.01.
Cylinder head refitment see Job Card 01.09.01.
© 0301 0299 6472-0125 JC 01 - Page 13

Cylinder head
01.04.01
Fig. 1 Cylinder head, In-line engine (83141_0)

f
JC 01 - Page 14 0299 6472-0125 © 0301

Cylinder head
01.04.01
Cylinder head removal, V-type engine
Tools
- Standard tools
- Hoist
- 4 thread protectors
Cross-references
- Job Card 01.08.01, 01.09.01, 02.16.01,
06.02.01
Job
Unscrew plug or open cock on crankcase to drain
water down to head bottom edge. Remove rocker
chamber cover (7). Disconnect lines for fuel injec-
tion (3), starting control air (6), nozzle coolant (8)
and (10), fuel backleakage (9) and rocker arm lubri-
fication (5). Remove liner retainer (4) from head
(20). While retaining adapter (24) by wrench, uns-
crew indicator valve (25).
Disconnect starting air pipe (2) on both sides of
cylinder head (20). To do this, unscrew bolts and
push sliding piece of starting air pipe (2) axially to
the right into the head. Charge air pipe (22) need
not be disconnected, provided spacers (21) are dis-
placed (Job Card 06.02.01).
Remove guard (13). Disconnect respective section
of water manifold (11) after releasing flanges and
displacing the sliding pieces. Water outlet pipe (14)
remains in the head. Disconnect inlet pipe (17) by
unscrewing bolts (5). Unscrew bolts (16) of exhaust
manifold.
Release annular nuts (19) by hydraulic tool (Job
Card 02.16.01) and remove along with washers. Put
four thread protectors on studs (18), choosing every
second stud for this purpose.
If thermocouples for exhaust temperature gauging
are provided, unplug coupling secured to the water
manifold.
Fit suspension device (1) and remove head (20) by
hoist. Also, be sure head (20) will not damage joint
faces, studs or pushrod cover tubes (23). Put down
head on a wooden support.
Cylinder head servicing see Job Card 01.08.01.
Cylinder head refitment see Job Card 01.09.01.
© 0301 0299 6472-0125 JC 01 - Page 15

Cylinder head
01.04.01
Fig. 1 Cylinder head, V-type engine (83407_0)
JC 01 - Page 16 0299 6472-0125 © 0301

Cylinder head
01.05.01
Inlet valve removal/refitment
Tools
- Standard tools
- Valve dismantling tool
- Lapping paper
Cross-references
- Job Card 01.01.01, 01.04.01, 01.05.05
Removing the inlet valve

After removing the cylinder head (Job Card
01.04.01), remove clamping cone (2) and springs
(3) and (4) with dismantling tool (Job Card
01.05.05). Removal of rocker arm is not required.
Take down spring cap (1), springs (3) and (4), spring
cap (5), rotator (7), and withdraw valve (6) down-
wards.
Clean valve components, inlet duct in head, head
base, and check valve seats.
Take off 0-seal (8).
For reconditioning see Job Card 01.07.01.
Refitting the inlet valve
Install new 0-seal (8) in valve guide. Introduce valve
(6) with motor oil and retain at bottom. Fit rotator (7),
spring cap (5), springs (4) and (3) and cap (1).
Check that close-coiled end of spring (4) is at bot-
tom. Mount dismantling tool (Job Card 01.05.05)
and install clamping cone (2).
Realease tool and remove.
Setting the valve clearance see Job Card 01.01.01.
Important
Should rust be present, eventually bringing about
extra pitting efects on valve stem and clamping
cone, smooth over same with lapping paper.
If this is not possible, renew valve complete.
Fig. 1 Valve (83142_0)
© 0301 0299 6472-0125 JC 01 - Page 17

Cylinder head
01.05.01
JC 01 - Page 18 0299 6472-0125 © 0301

Cylinder head
01.05.02
Removing and installing the exhaust valve cone, DEUTZ rotating device
Tools Spare parts

- Normal tools - Sealing rings
- Spacer
Cross-references
- Sickle spanner 80/90
- Job Card 01.01.01, 01.05.03, 01.05.05
- Valve dismantler
Aids
- Molybdenum sulfide (DEUTZ S3)
- Clean oil
Note
The exhaust valve cone must be removed AFTER
removing the exhaust valve cage (see Job Card
01.05.03).
Removing the DEUTZ rotating device
Unscrew hexagon-head screw (7). Take off connec-
ting link (8), being careful with the dowel pin (11).
Unscrew hexagon-head screws (9), and take off
driver (10).
Hold spring plate (1) in place with the sickle spanner
and unscrew clamping nut (3) with spacer (22). Take
our spring washer (4) and bush (5); see Fig. 2.
To remove the clamp cone (6), use valve dismantler
as detailed in Job Card 01.05.05.
Take off free-wheel with spring plate (1), compres-
sion springs (13) and (14), spring plate (16), disk
(17), axial bearing (18) and bush (15).
Fig. 1 Exhaust valve with DEUTZ rotating device

(83143_1)
© 0301 0299 6472-0125 JC 01 - Page 19

Cylinder head
01.05.02
Removing the exhaust valve cone

Pull out valve cone (21) downwards from the valve
cage (20). Lean valve parts, exhaust gas channel in
the cylinder head and valve cage. Remove round
sealing ring (12).
Installing the exhaust valve cone
Replace round sealing ring (12), and insert in the
valve guide (19). Insert valve cone (21) with oiled
shaft in the guide. Hold valve cone (21) in position.
Installing the DEUTZ rotating device
In the area of the lower spring plate (16), coat the
valve guide (19) with molybdenum sulfide (DEUTZ
S3). Also coat bush (15) with DEUTZ S3, and insert
together with axial bearing (18) (for installation con-
figuration, see Detail Y of Figs. 1 and 3).
Fig. 2 Detail X, clamping nut spacer (83149_1) Fit disk (17), spring plate (16), compression springs
(13) and (14), free-wheel with spring plate (1). Note
that the large compression spring (13) must be
installed in such a way that the closer-together turns
are located downwards on the cylinder head.
Mount clamping cone (6), using valve dismantler as
detailed in Job Card 01.05.05.
Insert bush (5) and spring washer (4). Hold spring
plate (1) in place with the sickle spanner, and tighten
clamping nut (3) with 70 Nm. The clamping nut (3)
must not be flush against the inner ring (2). Use a
feeler gauge to measure the clearance between the
clamping nut (3) and the inner ring (2).
Fit connecting link (8) with dowel pin (11), and tigh-
ten hexagon-head screws (7) with 40 Nm. To secure
driver (10), mount hexagon-head screws (9) with
approx. 20 Nm.
Fill the free-wheel with clean oil through the top four
boreholes.
Adjusting the valve clearance:
Fig. 3 Detail Y, DEUTZ rotating device (83144_1)
JC 01 - Page 20 0299 6472-0125 © 0301

Cylinder head
01.05.02
Removing and installing the exhaust valve cone, Rotocap rotating de-
vice
Tools Cross-references
- Normal tools - Job Card 01.01.01, 01.05.03, 01.05.05
- Valve dismantler
Aids
- Molybdenum sulfide (DEUTZ S3)
- Clean oil
Spare parts
- Sealing rings
Note
The exhaust valve cone must be removed AFTER
removing the exhaust valve cage (see Job Card
01.05.03).
Removing the Rotocap rotating device
To remove the clamping cone, use the valve dis-
mantler as detailed in Job Card 01.05.05. Take off
spring plate (1), compression springs (4) and (5),
spring plate (6), rotating device (7) and disk (8).
Removing the exhaust valve cone
Pull out valve cone (11) downwards from the valve
cage (9). Clean valve parts, exhaust gas channel in
the cylinder head and valve cage. Remove round
sealing ring (3).
Installing the exhaust valve cone
Replace round sealing ring (3), and insert in the
valve guide (10). Insert valve cone (11) with oiled
shaft in to the guide. Hold valve cone (11) in posi-
tion.
Fig. 1 Exhaust valve with Rotocap rotating device

(83145_1)
© 0301 0299 6472-0125 JC 01 - Page 21

Cylinder head
01.05.02
Installing the Rotocap rotating device

In the area of the lower spring plate (6), coat the
valve guide (10) with molybdenum sulfide (DEUTZ
S3).
Spray oil into the rotating device (7) between spring
plate and the main body.
Fit disk (8), rotating device (7), spring plate (6), com-
pression springs (4) and (5) and spring plate (1).
Note that the large compression spring (4) must be
installed in such a way that the closer-together turns
are located downwards on the cylinder head.
Mount clamping cone (2), using valve dismantler as
detailed in Job Card 01.05.05.
Adjusting the valve clearance:
JC 01 - Page 22 0299 6472-0125 © 0301

Cylinder head
01.05.03
Removing and installing the exhaust valve cage
Tools Aids
- Normal tools - Lubricant DEUTZ S1
- Lifting tackle - Molybdenum sulfide (DEUTZ S3)
- Valve cage pull-out device, 0204 7466
Cross-references
- Job Card 01.01.01, 01.04.01, 01.05.04,
01.07.03
- Tightening Instructions
Removal
Take off cylinder head hood (1). Put the piston of the
cylinder concerned to its ignition TDC position. Shut
off coolant for the valve cages, if any, with stop
valve (2) turned to "OFF". Otherwise, drain off coo-
lant from the cylinder head. Remove shock-absor-
ber rod lock (14). Unscrew hexagonal nuts (12).
Unscrew the pressure screws (11) of the exhaust
valve lifter (10) far enough to enable the shock-
absorber rod to be pushed to one side. Swing
exhaust valve lifter (10) and transmission valve lifter
(13) out wards. Identify cage flanges with punched
letters: "I" (near the indexing valve) and "A" (near
the exhaust valve). This defines the installation loca-
tion for reworking and installation. Unscrew hexago-
nal nuts (8) of the valve cage mountings. Take off
sleeves (9).
Mount valve cage pull-out device with suspension
bracket (7) and traverse (6). By turning the spindle
(5) inwards, pull up the valve cage, thus detaching
it. Take off the traverse (6), and use lifting tackle to Fig. 1 Stop valve (83146_1)
raise the valve cage out of the cylinder head.
Remove seal (22).
© 0301 0299 6472-0125 JC 01 - Page 23

Cylinder head
01.05.03
Fig. 2 Valve actuator (83147_1)
Fig. 4 Exhaust valve (83150_1)
Fig. 3 Pull-out device (83148_1)

Caution!
If the valve cage cannot be detached, the
cylinder head will have to be removed as
detailed in Job Card 01.04.01, and the
valve cage pushed out of the cylinder head
from below.
For check routines and any maintenance required,
see Job Cards 01.05.04 and 01.07.03.
Clean valve cage location hole and seals support in
the cylinder head.
JC 01 - Page 24 0299 6472-0125 © 0301

Cylinder head
01.05.03
Installation Tightening Instructions

Replace all 4 round sealing rings (23). Preliminary tightening: 70 Nm
Note ● Tighten fixing nuts (see Fig. 5) in the sequence
Only thermally stable Viton round sealing rings may M1, M2, M3, M4.
be used. Post-tightening angle: 270°
Coat these sealing rings with DEUTZ S1 grease to ● Tighten fixing nuts (see Fig. 5) in 3 stages, each
DEUTZ Standard H0685, Ordering No. 0100 7277. of 90°.
Replace sealing ring (22). Sequence per stage: M1, M2, M3, M4
To guard against sticking, coat the outer surface of

the valve cages as far as the lower round sealing
ring with molybdenum sulfide (DEUTZ S3).
Use lifting tackle to insert valve cage assembly into
the cylinder head.
Put the valve cage (21) into position, if necessary
using a hardwood block and a hammer. Fit sleeves
(9). Screw on hexagonal nuts (8), and tighten them
in accordance with the following tightening instruc-
tions.
Swing over exhaust valve lifter (10) and transmis-
sion valve lifter (13). Put shock-absorber rods into
position. Fit shock-absorber rod lock (14). Adjust
valve clearance as detailed in Job Card 01.01.01.
Open coolant stop valve (2) by turning it to "ON", or
top up with coolant. Fit cylinder head hood (1)
(01.08.02).
Caution!
Check drainage boreholes (20) for exhaust
valve cage at the cylinder heads, to see if
water and/or oil is escaping; Fig. 5 Fixing nuts (83406_2)
see Fig. 2. Note
When a valve cage's fixing nuts are loosened, the
fixing nuts of the second valve cage must also be
loosened, and tightened in accordance with the
instructions above.
© 0301 0299 6472-0125 JC 01 - Page 25

Cylinder head
01.05.03
This page has been intentionally left blank.
JC 01 - Page 26 0299 6472-0125 © 0301

Cylinder head
01.05.04
Inlet and exhaust valves inspection
Tools
- Standard tools
- Endoscope with perforated ring and two
special wrenches (optional)
Cross-references
- Job Card 07.07.01, 01.07.03
Inspection
Without cylinder head removal, the valves can be
inspected when using the endoscope. On this occa-
sion, the entire combustion chamber can be inspec-
ted.
Note
The endoscope is available from this Company with
transformer from 220 v.a.c.
Job
Refitting the valve
Remove rocker chamber cover. Thurn piston to sca-
venging (valve overlap) TDC. Remove injector (Job
Card 07.07.01) and clean its seats in head (5). Intro-
duce guide tube through injector seat hole.
Connect endoscope (2) to transformer, introduce
into guide tube (4) and, at weak lighting, let down
until valve seat is visible. Retain endoscope by
slightly tightening cheese-head screws in locking
ring (3).
Caution!
Use endoscope, if possible, with max. 11 V
no longer than necessary to prevent hea-
ting up. Never touch lamp nor distort or
strike endoscope
Handle with care!
Fig. 1 Endoscope (83151_0)
© 0301 0299 6472-0125 JC 01 - Page 27

Cylinder head
01.05.04
Inspecting the valve

Turn endoscope until valve seat is in full view. Loca-
tion of stem (6), seat (7) and plate (8) see “X”. A
pointer (1) at the endoscope top shows the direction
of viewing. (note that valves appear turned upside
down.)
Vary light intensity with the regulator on the transfor-
mer. If you are irretated by dazzling effect, vary
endoscope level.
Valves fitted with Rotocap rotators are turned, by
means of hole ring and long special wrench (10). To
this end, insert hole ring with both pins into tapholes
of spring cap and wrench with both pins into holes of
ring.
Valves fitted with DEUTZ rotators are turned by the
short special wrench (11). To do this, insert wrench Fig. 2 Valve seat (83152_0)
direct into recess of rotator castle nut. )
Once light intensity and focus are correctly adje-
sted, even minor valve seat flaws like pittings can
be recognized. The view will become more stereos-
copic by slightly turning endoscope and valve.
Throat passages will be easily recognizable.
Inspect entire valve seat periphery by turning valve.
Where isolated pittings are discovered, valve recon-
ditioning depends on the size of such pittings.
However, should such pittings cover the entire peri-
phery, recondition valve immediately (Job Cards
01.07.01 and 01.07.03).
When inspection is completed, remove endoscope
and reinstall injector (Job Card 07.07.01).
Fig. 3 Special wrench (83153_0)
Fig. 4 Reamer (83154_0)
JC 01 - Page 28 0299 6472-0125 © 0301

Cylinder head
01.05.05
Valve springs removal/refitment
Tools
- Valve dismantling tool
Cross-references
- Job Card 01.05.01, 01.05.02
Job
Caution!
When performing work with cylinder head
mounted, place piston in TDC position.
Take valve jack (1) to (4) out of spindle bush (9).
Turn jack bush (3) up to top stop (2). See that jack
engages with its 3 dogs (4) in groove of valve stem
(11). (To begin with, tilt jack, so dogs will open more
easily.) Screw bush (3) down until dogs securely
grip the valve stem.
Caution!
When dogs (4) do not exactly engage in
groove of stem (11), they are liable to slip
out, so the tool will suddenly be shot up
through the loaded springs.
Put spindle sleeve (10) on spring cap (12) (Rotocap
rotator) or on outer ring (DEUTZ rotator) and couple
jack to the rest of the tool by bush (9). Turn pin (6) to
compress springs and take out clamping half-cones
(5).
Where no exhaust valve cages are installed in the
cylinder head, introduce suitable retaining device (8)
into recess of spindle sleeve (10) just below guide Fig. 1 Valve dismantling tool (83155_0)
plate (7), but not below spindle bush (9). Unload
springs completely and remove jack from bush (9).
Where head and cages are fitted, lower valve stem
(11) by jack (1) s l o w l y so it cannot strike a piston
located in TDC. Leave jack (1) and stem (11) toge-
ther, so the valve cannot drop into the combustion
chamber.
Where head and cages are removed, screw jack
bush (3) upwards. Take dogs (4) out of groove of
stem (11), taking care that valve will not fall out.
Refitment is made in the reverse order.
© 0301 0299 6472-0125 JC 01 - Page 29

Cylinder head
01.05.05
JC 01 - Page 30 0299 6472-0125 © 0301

Cylinder head
01.06.01
Valve guide inspection/reconditioning
Tools
- Standard tools
- Drift (copper)
Cross-references
- Job Card 00.03.01, 01.04.01, 01.05.01,
01.05.02, 01.07.01, 01.07.03
Inspection Caution!
Check valve guide clearance when reconditioning Do not strike undercooled guide in view of
valves. its brittleness!
Job If undercooling is not practicable, e.g. on board ship,
Pull valve out of guide. Clean both. Measure guide drive home guide carefully with a cooper drift and
bore over some 10 mm at top and bottom. Guide hammer of about 2 kg for the inlet valve and a suita-
replacement is due when bore exceeds 22.4 mm ble copper drift for the exhaust valve cage. Strike in
(inlet) or 22.4 mm (exhaust) (s. Fig. 2) at any point. direction of centre line. Check that guid collar firmly
contacts cylinder head or plate (3).
Reconditioning
After guide replacement, grind valve (Job Cards
Note 01.07.01 and 01.07.03).
Guide replacement does not call for seat insert
replacement.
Replacing the guide
Drive out guide (4) by copper drift from inlet/exhaust
duct in head or from cage, as applicable. Be sure
not to damage bore in head or cage. Trim any high
spots by scraper.
Exhaust valve:
After undoing grub screw (5), remove plate (3) and
renew 0-seals (2), if necessary.
Carefully clean new valve guide (4) and receiving
bore. Undercool guide in nitrogen bath (see Job
Card 00.03.01) and install immediately.
© 0301 0299 6472-0125 JC 01 - Page 31

Cylinder head
01.06.01
Fig. 1 Inlet valve guide (83156_0)
Fig. 2 Exhaust valve guide (83157_0)
JC 01 - Page 32 0299 6472-0125 © 0301

Cylinder head
01.07.01
Maintaining the inlet and exhaust valve cones
Tools
- Normal tools
- Gauge for valve disk thickness
- Clamping device for valve spindle
- Hunger valve cone grinding machine
VKM 2.3 (or VKM 4)
Cross-references
- Job Card 01.03.02, 01.04.01, 01.05.01,
01.05.02, 01.05.03, 01.05.04,
01.05.05, 01.06.01, 01.07.03
- Operating Instructions, Messrs Hunger
Maintenance scheduling for inlet valves Work sequence

As a rule, the valves are maintained in accordance Inlet valves
with a maintenance interval plan, unless, for - Removing the inlet valve,
example, irregularities occur at a particular cylinder. see Job Card 01.05.01.
If you have an option for checking the valves with an
endoscope as detailed in Job Card 01.05.04, then - Checking the rotating device,
you can specify the schedule for valve maintenance see Job Card 01.03.02.
yourself n the basis of the assessment obtained. - Checking the valve guide clearance,
Maintenance scheduling for exhaust valves see Job Card 01.06.01.
Poor condition of the engine (soiled exhaust gas tur- - Given the inlet valve a thorough cleaning.
bocharger, intake air filter or intercooler, inadequate Examine the valve and particularly the valve seat
condition of the injection valves, etc.) or impermissi- Exhaust valves
ble duty conditions, may lead to thermal overloading
- Removing the exhaust valve,
of the valves, with serious consequences. So you
see Job Card 01.05.03 and 01.05.02.
must continually monitor the operating data as set
out in the acceptance test report, particularly the - Checking the rotating device,
exhaust gas temperature at all cylinders. If the see Job Card 01.03.02 and 01.03.03.
exhaust gas temperature at individual cylinders sud- . Checking the valve guide clearance,
denly begins to rise, you have to suspect leaking see Job Card 01.06.01.
exhaust valves. Usually, the valves are maintained
- Check axial bearing (17). If needles of the axial
in accordance with a maintenance interval plan,
bearing or disk (16) are damaged, replace them
unless (as remarked above) there is a suspicion of
(see Job Card 01.05.02, Figs. 1 and 3)
leaking valves. If you have an option for checking
the valve with an endoscope as detailed in Job Card - Give exhaust valve a thorough cleaning. To
01.05.04, you can specify the schedule for valve make it easier to remove water-soluble residues
maintenance yourself on the basis of the with a sulfur content, valve housing, cone and
assessment obtained. seat rings can be placed in water for several
hours. If the valve housing is not going to have
Note
treated engine coolant flowing through it imme-
If there is an uneven contact pattern or other signs diately afterwards, conserve the cooling com-
of slight leaks, or if there are relatively deep imapct partment.
markings or unevennesses, you have to rework the
valve cone and the valve seat rings with grinding or
turning tools (see under repairs or the Job Card for
valve seat rings 01.07.03).
© 0301 0299 6472-0125 JC 01 - Page 33

Cylinder head
01.07.01
Note Reworking the valve cone seat surface

Special care MUST be taken when transporting, The seat surface must be reworked if
storing and maintaining these parts. Even for unfa- - the cleaned seat surface is not free of coke
vorable conditions (e.g. rough seas), you must impacts and surface damage,
ensure that the valve cones cannot damage each
other (e.g. knock against each other), that they do - the eccentricity of the otherwise faultless seat
not call, corrode and thus suffer damage. surface d (see Fig. 5) to the stem is greater than
0.2 mm (Fig. 4).
Checking the inlet and exhaust valves
Note
Preconditions for further use
The values for the rework limit of the valve cone
- Seat surface without coke impacts, burn-throu- seat surface will depend on the outer diameter of
ghs, or cracks. If coke impacts and/or surface the valve cone, and can be taken from the diagrams
defects are found, they have to be eliminated in Figs. 2 and 3.
until they comply with the permissible limit
dimensions as shown in Figs. 2 and 3. Example:
After turning off the outer diameter of the exhaust
- In the areas X and Y in Fig. 4, no interruption of valve cone to 112.9 mm, the minimum permissi-
the metallic surfac coating (chromium-plated), ble disk thickness Hmin is 4.99 mm, see Fig. 3.
- between the areas X and Y
- no corrosion scar deeper than 0.3 mm,
- stem diameter D at no point(due to area cor-
rosion) smaller than 21.0 mm,
- Concentricity at seat surface and stem within
permissible limits as shown in Fig. 4, i.e. the
eccentricity of the cleaned seat surface to the
stem is at most 0.2 mm; to do this, fix stem for
measurement purposes at the points A and B
designated in Fig. 4 on prisms, and axially by a
stop at the stem's end.
Enter the measured values on the appropriate mea-
surement sheet at the end of the Job Card.
Caution!
NEVER straighten the valve cone, nor
warm it up with the welding flame!
Fig. 1 Reference surface A (83493_0)
JC 01 - Page 34 0299 6472-0125 © 0301

Cylinder head
01.07.01
5,9
NG
VG geschliffen
Ra 0,4
NG
0,8
Hmin [mm]
Serie
4,9
5,9
4,9
∅ 114
∅ 116 ∅ 114 ∅ [mm] ∅ 116
(r = 57) (r = 58)
Fig. 2 Inlet valve cone (83496_0)
NG
5,4
VG geschliffen
Ra 0,4
NG
0,9
Hmin [mm]
Serie 4,99
4,5
5,4
4,5
∅ 112 ∅ 112,9
∅ 113,9 ± 0,1 ∅ 112 ∅ [mm] ∅ 113,9 ± 0,1

(r = 56) (r = 56,95 ± 0,05)
Fig. 3 Exhaust valve cone (83495_0)
A Reference surface geschliffen ground
NG Rework limit Serie Series
VG Wear limit
Hmin Height (disk thickness)
© 0301 0299 6472-0125 JC 01 - Page 35

Cylinder head
01.07.01
Fig. 4 Valve (83475_0)

V = before reworking the seat surface IN = inlet
N = reworked seat surface EX = exhaust
Fig. 5 Valve seat (83160_0)

Seat surface with a worse appearance than Fig. 5
must always be reworked.
JC 01 - Page 36 0299 6472-0125 © 0301

Cylinder head
01.07.01
Repair Remove the grinding disk immediately you have

Reworking of the seat at the cone and the valve worked a valve cone, since the material will smear
seat must ensure that a continuous contact pattern the grinding disk.
of 70% seat width is achieved, beginning from the The grinding operation can be halted when on the
outer diameter (outer contact pattern). This mea- entire circumferential seat surface - at quadruple
sure is aimed at ensuring that the cone seat is flush magnification under a magnifying glass - no resi-
against the valve seat for a gastight seal under ope- dues or surface damage at all are any longer to be
rating conditions. seen. Here you MUST pay special attention to the
Values for reworking the valve cone with the grin- outer edge of the seat and the circumferential edge
ding machine can be found in Figs. 2 and 3. at the transition between the seat surface and the
outer diameter of the disk (see Fig. 7).
The grinding machine must be adjusted in accor-
dance with the contact pattern roughness stated
above.

If reworking causes the dimensions of the valve
Fig. 8 Valve seat (83163_1) disk, Figs. 2 and 3, to fall below the specified mini-
Work sequence mum, then you have to replace the cone. You can
use the gauge as shown in Fig. 9 to check the valve
If, for example, in the case of exhaust valves the disk thickness. The valve cone can continue to be
disk outer diameter has been damaged by the used if Dimension "Y", Fig. 9, is greater than 1 mm.
effects of combustion or corrosion on the surface, The gauge is not suitable for assessing or determi-
this damage must be remedied before you actually ning the correct seat angle.
start to machine the seat. For this purpose, the outer
diameter must be turned off on a lathe. In order to check the contact pattern of the cone
seat and the associated valve seat, all reworked or
The permissible limit dimensions for disk outer dia- new valve cones must be lightly ground on the valve
meter and disk thickness as shown in Figs. 2 and 3 cage clamped in the cylinder head with the aid of
must not be exceeded. the clamping device (see Fig. 10), but without the
To clamp the cone and machine the seat surface, round sealing ring for sealing off the stem (e.g. only
follow the operating instructions of Messrs Hunger. perform a check-grinding routine, not full grinding-
in)
To avoid chatter marks, the grinding machine must
be placed on a stable surface to preclude vibrations. Do not use water-soluble grinding paste, but a fine,
When grinding, work with slight forward feed, so as oil-soluble type, with a grain size of 13 µm.
to minimize chip removal and chatter mark effects. When grinding, lift the valve cone at short intervals,
During the rework operation, a cooling medium con- and put it back against the seat ring in a different
sisting of 95 % water and 5 % lubricating and coo- position.
ling concentrate, e.g. Harriol L 12, must be used.
The aim of this light grinding is to monitor the outer
contact pattern of the valve cone on the seat ring
(check-grinding routine), see Fig. 8.
© 0301 0299 6472-0125 JC 01 - Page 37

Cylinder head
01.07.01
Fig. 10 Clamping device (50159_0)

Then remove ALL grinding residues with gas oil.
The partners ground in to suit each other have to
stay together.
JC 01 - Page 38 0299 6472-0125 © 0301

Cylinder head
01.07.01
Inlet valve data sheet

Date of inspection: ............
S Exhaust manifold
L Air manifold
L Left (indicating side)
R Right (starting side)
Engine-No.
Running hours total
Running hours since

last inspection
Fig. 12 Inlet valves, V-type engine (83393_0)
Fig. 11 Inlet valves, In-line engine (83165_0)
Fig. 13 Valve (83475_0)

© 0301 0299 6472-0125 JC 01 - Page 39

Cylinder head
01.07.01
Cyl. Running Stem - ø Deflection at Disc thick- Disc ø Reworking Renewal

No. hours D seat ness yes/no yes/no
L R L R L R L R L R L R L R
6
7

A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
B3
B4
B5
B6
B7
B8
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Cylinder head
01.07.01
Exhaust valve data sheet

Date of inspection: ............
S Exhaust manifold
L Air manifold
L Left (indicating side)
R Right (starting side)
Engine-No.
Running hours total
Running hours since

last inspection
Fig. 15 Exhaust valves, V-type engine (83394_0)
Fig. 14 Exhaust valves, In-line engine (83168_0)
Fig. 16 Valve (83475_0)

© 0301 0299 6472-0125 JC 01 - Page 41

Cylinder head
01.07.01

6
7

A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
B3
B4
B5
B6
B7
B8
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Cylinder head
01.07.02
Inlet valve seat insert removal/refitment
Tools
- Standard Tools
- Feeler gauge 0.05 mm
- Electric welding unit
- Removing/Refitting device (optional)
Cross-references
- Job Card 01.06.01,01.07.01
Note
When a valve seat insert is replaces (Job Card
01.07.01), check guide bush for wear (Job Card
01.06.01).
Removing the insert
Apply two heavy opposing beads (3) of about
50 mm length by normal steel electrodes to inner
diameter of insert (2). At least two layers of beads
(3) should be applied (see Detail “X”).
do not heat with welding flame!
Take care that no globules fall into the cylinder
head. Remove valve seat insert immediately. This is
usually possible without the aid of pulling device (1).
Fitting the new insert
Receiving bore Ø125 + 0.025 cylinder head must be
perfectly clean, undamaged, and of correct dimen- Fig. 1 Pulling device (83169_0)
sion. Undercool new insert (2) in nitrogen bath (see
Section 3.8) and fit into cylinder head (5).
Do not strike with a hammer, etc., sinde undercoo-
led inserts are brittle. If you do not have a nitrogen
bath, undercool insert to at least -20 °C, lightly oil
the outer circumference and pull in with device (4).
Always check the fit of the insert in the cylinder
head.
It is permissible to be able to insert a feeler gauge of
not more than 0.05 mm between valve seat insert
and cylinder head shoulder, but only to a uniform
depth over the entire periphery. Otherwise, a new
insert must be fitted.
© 0301 0299 6472-0125 JC 01 - Page 43

Cylinder head
01.07.02
Fig. 3 Tool (83171_0)
JC 01 - Page 44 0299 6472-0125 © 0301

Cylinder head
01.07.03
Maintaining the inlet and exhaust valve seat rings
Tools Cross-references
- Normal tools - Job Card 01.05.01,05.05.02, 01.05.03,
01.05.04, 01.06.01, 01.07.01, 01.07.02
- Mounting swivel block for cylinder head
- Operating instructions from Messrs
- Reserve cylinder head
Hunger
- Hunger valve seat grinding machine
SB 3 or
Hunger valve seat lathe VDS 2.5E,
Obtainable from: DEUTZ AG, Cologne
Deutz-Mülheimer Str.
Dept. VS-VSWK
Gate 12
- Sample piece Rz4 (e.g. half seat ring)
Maintenance To simplify handling of the cylinder head, it is advi-

The valve seats must always be maintained in con- sable to fit this in a mounting swivel block. After both
junction with the inlet and exhaust valves as detai- valve housings have been inserted, the head is tur-
led in Job Card 01.07.01. ned, and the combustion chamber surface brought
to a horizontal position.
Note
Make sure that the mounting swivel block is placed
If you have an option for checking the guide seat in a configuration where vibrations are precluded.
rings with an endoscope as detailed in Job Card
01.05.04, then you can specify the scheduling for In the case of the inlet valve, the seat rings are
seat ring maintenance yourself on the basis of the reworked in the removed cylinder head; note that
assessment obtained. here, too, the valve guide must be checked before-
hand as detailed in Job Card 01.06.01. If it should
Checking the inlet and exhaust valve seat rings be recognizably be no longer possible to rework the
The seat rings can continue to be used if inlet valve seat rings should in compliance with the
limit dimensions (see Fig. 1), then they have to be
- there are no coke impacts, burn-throughs or
replaced. For removal and installation of the inlet
cracks,
valve seat rings, see Job Card 01.07.02.
- any existing shape/surface damage can be
For set-up and handling of the valve seat grinding
reworked in compliance with the permissible limit
machine or lathe, please consult the operating
dimensions (see Fig. 1, 3 and 4).
instructions from the Hunger company. In addition,
Repair comply with the section entitled "Handling the guide
Preconditions for correct reworking of the valve seat pilot" in this Job Card.
rings are a proper valve guide (see Job Card If the work is performed properly, this will achieve
01.06.01) and cleaned chamfers for accepting the the desired position and shape tolerance as shown
guide pilot. in Figs. 1, 3 and 4. When grinding, rework as econo-
In the case of the exhaust valve sea ring, the valve mically as possible with small forward feed; comp-
housing must be clamped ion a cylinder head lying with the instructions will ensure that the
(reserve cylinder head) using a new soft-iron contact pattern, plus the position and shape toleran-
sealing ring and in compliance with the tightening ces - see Figs. 1, 3 and 4 - are achieved.
instructions as detailed in Job Card 01.05.03.
© 0301 0299 6472-0125 JC 01 - Page 45

Cylinder head
01.07.03
After reworking, check concentricity with the measu-

ring tool supplied by Messrs Hunger. I.e., the guide
pilot remains installed, and a stop ring with the dial
gauge holder and the dial gauge is set up. Then run
over the seat ring with the dial gauge, compare the
18 -0,1
values obtained with the specifications, and record
them.
If the limit dimensions is exceeded, or if the stellite
Z
layer (exhaust valve seat ring) is no longer present
over the entire width at any point of the seat circum-
ference (armoring "light", base material "dark"), then 0,02 A 45˚ 4' ± 3'
the entire valve cage has to be replaced. 0,02 Xmax <= 120
In order to check the contact pattern of the housing 0,01
seat with the associated cone, mark the housing Rz 4
seat with 8 to 12 pencil lines (soft lead "B") and turn
the inserted cone with the ball of your thumb under Fig. 1 Inlet valve seat ring (83172_1)
light pressure in pendulum fashion by a maximum of
+/-30°. When you do this, an even contact must be
produced over the entire circumference, whose A Inlet valve guide borehole as reference
width is 70 % of the seat width and begins at the surface
outer diameter. Xmax maximum dimension for reworking
The contact pattern must also be checked using
what is called a check-grinding routine. For this pur- Z do not rework
pose, lightly grind over the cone with the aid of the
clamping device on the seat ring. Use fine grinding
paste with a grain size of 13 µm.
It is not permissible to simply rework the seats by
grinding them in with grinding paste without using
the grinding machine or lathe.
Before being re-inserted, the valve cage must be
checked for leaks and coolant throughflow.
For the throughflow check, position the valve cage
(with inlet and outlet boreholes facing upwards)
horizontally. Pour water in at one opening until the
liquid exits unimpeded from the other borehole. If
the cooling channel does not exhibit adequate
throughflow, it must be cleaned with a scale-dissol-
ving agent which will not attack the material, e.g.
with SAF Acid, Porodox, Vecom BA-S, Vecom BA-
30.
Caution!
When using these cleaning agents with an
acid content, all associated safety instruc-
tions from the manufacturer concerned
must be complied with.
If the seat ring is not going to have engine coolant
flowing through it immediately afterwards, conserve
the cooling compartment. The valve housing with its
valve cone can then be completed again as detailed Fig. 2 Reference surface A (83497_0)
in Job Card 01.05.02.
JC 01 - Page 46 0299 6472-0125 © 0301

Cylinder head
01.07.03
Exhaust valve cage, old version Exhaust valve cage, new version
Part No: 0404 6109 KC Part No: 0404 6752 UC
21 -0,1
21 -0,1
Z
Z
0,02 A 45˚ 4' ± 3' 0,02 A 45 4’ – 3
0,02 Xmax <= 120 0,02 Xmax <= 117,5
0,01 0,01
Rz 4 Rz 4
Fig. 3 Exhaust valve cage (83492_0) Fig. 4 Exhaust valve cage (83174_2)
A Exhaust valve guide borehole as refe-

rence surface
Xmax maximum dimension for reworking
Z do not rework
Fig. 5 Reference surface A (83494_0)
© 0301 0299 6472-0125 JC 01 - Page 47

Cylinder head
01.07.03
Handling the guide pilot

The guide pilot from Messrs Hunger is intended for
guiding the valve seat grinding machine or lathe. It
is used at both the inlet and the exhaust valve seats.
Check the eccentricity at the guide pilot from time to
time: it should not exceed 20 µm. For this purpose,
hold the guide pilot between the tips, and measure
the concentricity at the cone of the spindle; see
Fig. 6.
Fig. 6 Guide pilot (83490_0)

15° bevels at its ends are provided for proper cen-
tering of the guide pilot in the valve guide. Before
inserting the guide pilot, these two bevels must be
cleaned using the hand milling device include din
the tool kit.
For additional support of the guide pilot, the support
cross must be mounted.
Mount type-referenced guide socket.
If these bevels are not provided on an old valve

guide, they must be produced using the same hand
milling device.
15˚
2,5
Fig. 7 Valve guide, 15° bevels (83491_0)
JC 01 - Page 48 0299 6472-0125 © 0301

Cylinder head
01.08.01
Cylinder head servicing
Tools
- Standard tools
Cross-references
- Job Card 01.02.03, 01.05.03, 01.06.01,
01.07.01, 01.07.03, 01.08.02, 01.11.01,
01.12.01, 07.08.01
Servicing
Clean head and inspect.
Note
Carbon deposits on the combustion chamber plate
and in the inlet and exhaust passages as well as
scale deposits in the water jackets will interfere with
proper heat transfer so as to cause damage to the
head.
Job
Remove all valves. Clean head bottom as well as
inlet and exhaust passages from carbon.
Inspect head bottom for cracks, especially close to
the inlet and exhaust valves and the injector.
Check that all joints are in good condition.
Inspect water transfer ports and head interior after
unscrewing plug (1) or removing cover plate (2).
Cleaning the water jackets will affect the entire coo-
ling system of the engine (section 6), and the need
for such operation will suggest unsuitable cooling Caution!
water. For proper water condition see section 6. Along with the head servicing be sure to
remove exhaust valve cages (Job Card
01.05.03) to prevent them seizing.
© 0301 0299 6472-0125 JC 01 - Page 49

Cylinder head
01.08.01
Along with head servicing carry out the following

further jobs:
Rocker arm bearing inspection
Job Card 01.02.03
Valve guide clearance checking
Job Card 01.06.01
Inlet valve reconditioning
Job Card 01.07.01
Exhaust valve reconditioning
Job Card 01.07.03
Injector inspection/testing
Job Card 01.08.01
Cylinder head shut-off valve reconditioning
Job Card 01.08.02
Starting valve inspection
Job Card 01.11.01
Safety valve inspection
Job Card 01.12.01
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Cylinder head
01.08.02
Cylinder head shut-off valve reconditioning
Reconditioning Tools
Whenever the shut-off valve should bind or the gas- - Standard tools
ket be leaky, remove valve.
Aids
- DEUTZ F5 compound
Job
Drain cooling water down to below heads.
Remove rocker chamber cover. Close valve in the
direction “X”.
Unscrew breather plug (5) half-way.
Drain rest of water. Retighten plug (5). Remove
lever (1) after lossening bolt (12). Unscrew hex. bolt
(7) and cheesehead screw (2). Take down lever (1).
Withdraw extension (6) with valve (4) and stop plate
(8) from guide sleeve (9). Withdraw sleeve from
head (11). Clean all components and check for cor-
rosion. Replace 0-seals (3) and (10).
Apply DEUTZ F5 compound on valve (4) and sleeve
(9) outside.
Insert sleeve into head (11). Push valve (4) with stop
plate (8) and extension (6) into sleeve (9). Fit lever
(1). Screw in hex. bolt (7) and cheesehead screw
(2) with lockwasher. Fit lever (1) by means of bolt
(12).
Open valve in the direction “Y”. Fill head with water.
Screw out of breather plug (5) half-way and, after
bleeding, retighten.
When refitting the rocker chamber cover make sure
that a gap of >= 1.5 mm remains between cast-on
boss on the cover and upper edge of plug. Other-
wise shorten boss on cover to gap >= 1.5 mm.
Check that no water comes out of drain “E”.
© 0301 0299 6472-0125 JC 01 - Page 51

Cylinder head
01.08.02
Fig. 1 Shut-off valve (83177_0)

A - B Water passage in cylinder head
C Cooling water inlet to exhaust valve
D Cooling water outlet from exhaust valve
E Drain
JC 01 - Page 52 0299 6472-0125 © 0301

Cylinder head
01.09.01
Cylinder head refitment, In-line engine
Tools Aids
- Standard tools - Cleaning agent FO 178
- Hoist - Spraying priming agent G 790
- 4 thread protectors - Silicone rubber VP 7293
Cross-references
- Job Card 01.01.01, 06.02.01, 02.16.01
Job Apply some grease to joint face of water inlet pipe

Carefully clean all joint faces. Replace all gaskets. (7). Fit new 0-seals on starting air pipe (11) and
Fit suspension device (18). Fit thread protectors introduce sliding pieces into head (8). If removed,
(22) on studs (17). refit water outlet pipe (3) with new 0-seal to head
(8).
© 0301 0299 6472-0125 JC 01 - Page 53

Cylinder head
01.09.01

Let down head until squarely seated. In doing so, Caution!
introduce pushrod cover tubes (20) from above into
The cylinder head nuts are to be tightened
the relevant holes in the rocker chamber (19).
with a pressure of p = 925+25 bar. This has
Check that head gasket between head and liner and to be done in 3 steps with the available
head in liner are properly located. Unscrew stud tool.
thread protectors. Apply lube oil to studs (17).
Tightening prescription:
Put washers (12) on studs (17) located outside of
- Tighten all round nuts by hand.
rocker chamber (19) (see also Job Card 02.16.01).
Screw annular nuts (13) in place. Remove suspen- Always put hydraulic tightening appliances
sion device (18). into starting-position.
Introduce starting air pipe (11) and push in sliding - Attach four hydraulic tightening appliances to
pieces on both sides of the head. round nuts 1 - 4 (see Fig. 3) (see Job Card
02.16.01).
Fit gaskets between head (8) and flanges of
exhaust pipe and water inlet pipe (7). Screw all bolts If there are eight hydraulic tightening
in place and then tighten securely. appliances available it is not necessary to
move them as described below.
Tighten cylinder-head round nuts hydraulically on
necked-down studs with a barrel diameter of Tightening of the round nuts in 3 steps:
27 mm. 1st step
- Pretighten up to a pressure of p = 200 bar and
tighten round nuts by hand using a tommy bar
(zero position and/or initial hole-counting point)
and mark round nuts if necessary.
- Reduce pressure to 0 bar by turning on high-
pressure pump handwheel.
2nd step
- Pump to raise pressure to p = 450 bar and tigh-
ten round nuts by hand using a tommy bar while
counting holes.
JC 01 - Page 54 0299 6472-0125 © 0301

Cylinder head
01.09.01
3rd step While retaining adapter 14 by wrench, screw indica-

tor valve (15) in place, taking care that its angular
- Pump to raise pressure to p = 925+25 bar and
position is correct (see figures).
while counting holes. The torque angle of steps 1 Set inlet/exhaust valve clearance (Job Card
to 3 must amount to 9 to 15 holes. Should this 01.01.01).
range of tolerance not be reached, look for Install rocker chamber cover (16) after inspecting
failure (e.g. error of assembly, faulty material, rocker arms for good funtioning including lubrica-
device or pressure gauge defective and others). tion. Tighten bolts (21) only moderately, to prevent
- Reduce pressure to 0 bar by turning on high- damage to gasket of cover (16).
pressure pump handwheel. Fill up engine coolant and check for proper condition
Moving the tightening devices (Section 6.4). Assemble plug-in coupling for built-on
exhaust thermocouples, if provided.
- Move the four hydraulic tightening devices onto
round nuts 5 - 8 (see Fig. 3) and repeat proce- Replace necked-down stud (17) (if required).
dure. Caution!
- Retighten round nuts 1 - 4.The connection is now Wear safety glasses for these operati-
mounted. Remove hydraulic tightening devices. ons.
Note: All 8 round nuts must be retightened after
100 operating hours.
- Clean blind holes; remove old sealing material
Refit guard (4) and pipe retainer, and connect piping either mechanically or with cold cleaning agent
for rocker amr lubrication, starting air, starting con- FO 178. Remove grease carefully from blind
trol air, fuel backleakage, nozzle coolant and fuel holes.
injection. Connect water manifold (11). Install adap-
- Prime necked-down stud by spraying priming
ters (9) of charge air pipe (10) (Job Card 06.02.01).
agent G 790.
Ventilating time: approx. 15 minutes.
Caution!
Smoking and naked flames prohibited wi-
thin a circle of 5 m; place danger signs;
can be removed 10 minutes after comple-
tion of operations.
- Fill threaded bottom of blind holes with approx.
17cm3 of silicone rubber VP 7293 while comp-
lying with the measure of 85 mm as per Figure 4.
- Screw necked-down stud into crankcase and
tighten to a torgue of 160 Nm.
- Allow rubber to harden for 8 hours at least after
completion of operations.
Fig. 4 Bolt (83181_0)
© 0301 0299 6472-0125 JC 01 - Page 55

Cylinder head
01.09.01
JC 01 - Page 56 0299 6472-0125 © 0301

Cylinder head
01.09.01
Cylinder head refitment, V-type engine
Tools Aids
- Standard tools - Cleaning agent FO 178
- Hoist - Spraying priming agent G 790
- 4 thread protectors - Silicone rubber VP 7293
Cross-references
- Job Card 01.01.01, 06.02.01, 02.16.01
Job
Carefully clean all joint faces. Replace all gaskets.
Fit suspension device (1). Fit thread protectors on
studs (18).
Apply some grease to joint face of water inlet pipe
(17). Fit new O-seals on starting air pipe (2) and
introduce sliding pieces into head (20). If removed,
refit water outlet pipe (14) with new O-seal to head
(20).
Let down head until squarely seated. In doing so,
introduce pushrod cover tubes (23) into bores for
tappet guides.
© 0301 0299 6472-0125 JC 01 - Page 57

Cylinder head
01.09.01
Caution!
The cylinder head nuts are to be tightened
with a pressure of p = 925+25 bar. This has
to be done in 3 steps with the available
tool.
Tightening prescription:
- Tighten all round nuts by hand.
Always put hydraulic tightening appliances
into starting-position.
- Attach four hydraulic tightening appliances to
round nuts 1 - 4 (see Fig. 3) (see Job Card
02.16.01).
If there are eight hydraulic tightening
appliances available it is not necessary to
move them as described below.
Tightening of the round nuts in 3 steps:
1st step
Fig. 2 Cylinder head, V-type engine (83408_0) - Pretighten up to a pressure of p = 200 bar and
Check that head gasket between head and liner and (zero position and/or initial hole-counting point)
head in liner are properly located. Unscrew stud and mark round nuts if necessary.
thread protectors. Apply lube oil to studs (18).
Put washers on studs (18) located outside of rocker pressure pump handwheel.
chamber (26) (see also Job Card 02.16.01). Screw
annular nuts (19) in place. Remove suspension 2nd step
device (1). - Pump to raise pressure to p = 450 bar and tigh-
Introduce starting air pipe (2) and push in sliding ten round nuts by hand using a tommy bar while
pieces on both sides of the head. counting holes.
Fit gaskets between head (20) and flanges of - Reduce pressure to 0 bar by turning on high-
exhaust pipe and water inlet (17). pressure pump handwheel.
Screw all bolts in place and then tighten securely. 3rd step
Tighten cylinder head round nuts hydraulically on - Pump to raise pressure to p = 925+25 bar and
necked-down studs with a barrel diameter of tighten round nuts by hand using a tommy bar
27 mm. while counting holes. The torque angle of steps 1
to 3 must amount to 9 to 15 holes. Should this
range of tolerance not be reached, look for
failure (e.g. error of assembly, faulty material,
device or pressure gauge defective and others).
Moving the tightening devices
- Move the four hydraulic tightening devices onto
round nuts 5 - 8 (see Fig. 3) and repeat proce-
dure.
- Retighten round nuts 1 - 4.The connection is now
mounted. Remove hydraulic tightening devices.
Note: All 8 round nuts must be retightened after
100 operating hours.
JC 01 - Page 58 0299 6472-0125 © 0301

Cylinder head
01.09.01
Refit guard (13) and pipe retainer (4), and connect Install rocker chamber cover (7) after inspecting rok-
piping for rocker arm lubrication (5), starting air, ker arms for good functioning including lubrification
starting control air (6), fuel backleakage (9), nozzle Tighten bolts (27) only moderately, to prevent
coolant (8) + (10) and fuel injection (3). Connect damage to cover (7).
water manifold (11). Install adapters (21) of charge Fill up engine coolant and check for proper condition
air pipe (Job Card 06.02.01). (section 6.4). Assemble plug-in coupling for built-on
exhaust thermocouples, if provided.
Replace necked-down stud (18) (if required).
Caution!
Wear safety glasses for these operati-
ons.
- Clean blind holes; remove old sealing material

either mechanically or with cold cleaning agent
FO 178. Remove grease carefully from blind
holes.
- Prime necked-down stud by spraying priming
agent G 790.
Ventilating time: approx. 15 minutes.
Fig. 3 Cylinder head (83531_0) Caution!
While retaining adapter (24) by wrench, screw indi- Smoking and naked flames prohibited wi-
cator valve (25) in place, taking care that its angular thin a circle of 5 m; place danger signs;
position is correct (see figures). can be removed 10 minutes after comple-
tion of operations.
Set inlet/exhaust valve clearance (Job Card
01.01.01). - Fill threaded bottom of blind holes with approx.
18 cm3 of silicone rubber VP 7293 while comp-
lying with the measure of 83 mm as per Figure 4.
- Screw necked-down stud into crankcase and
tighten to a torgue of 160 Nm.
- Allow rubber to harden for 8 hours at least after
completion of operations.
Fig. 4 Bolt (83431_0)
© 0301 0299 6472-0125 JC 01 - Page 59

Cylinder head
01.09.01
JC 01 - Page 60 0299 6472-0125 © 0301

Cylinder head
01.10.01
Cylinder head inspection
Inspection Tools
Check proper function of all related components - Standard tools
Aids
Cross-references
- Job Card 01.05.03
Job When refitting the rocker chamber cover (2) after

Inspection the head externally closing of plug on shut-off valve make sure that a
gap of >= 1.5 mm remains between cast-on boss on
Check that head (7) is dry. Should oil leak out, the cover and upper edge of plug. Otherwise shor-
inspect gaskets (1), (3), (5) and (6) and renew if ten boss on cover to gap >= 1.5 mm.
defective. If oil leaks out at joint (5) between rocker
chamber (4) and head (7), apply DW 47 sealing
compound. Inspect connections of engine coolant,
injector coolant, charge air, exhaust manifold, lube
oil and fuel injection piping.
Check the drainage borehole (8). If coolant is
exiting, replace the round sealing rings of the
exhaust valve cages (see Job Card 01.05.03).
Caution!
Rocker arm lubrication pressurized.
Inspecting inlet and exhaust valves
Run engine at lowest speed, remove rocker camber
cover (2) and check valves for even motion and
springs for freedom from defects.
Note
Before refitting cover (2), clean seat on chamber (4)
and check that gasket (3) of cover (2) is intact.
When replacing the seal (3), stick it to the cylinder
head hood (2) with DEUTZ DW 48 sealing com-
pound.
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01.10.01
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Cylinder head
01.11.01
Starting valve inspection/testing
Tools
- Standard tools
- Hex. bolt M6
- Testing outfit
Cross-references
- Job Card 01.11.02, 02.00.01
Inspection
Check that valve moves freely and is free from
leaks.
Note
A leaky starting valve can be recognized on the run-
ning engine by the starting air pipe connectors bet-
ween the cylinder heads becoming hot which may
even lead to the paint coming off.
Caution!
Prior to any dismantling, including discon-
nection of control air piping, be sure to read
the safety precautions provided (Job Card
02.00.01).
Checking valve for free moment
Disconnect control air pipe (4) and detach cover (5).
Mount testing outfit on cylinder head (16) (Fig. 2)
and push down piston (8) by lever (22) in the arro-
wed direction. If piston offers undue restance, ser-
vice valve (Job Card 01.11.02).
Apply some droplets of lube oil to plunger (8). Refit
cover (5) and reconnect control air pipe.
Checking valve for freedom from leaks
Unscrew control air pipe running from master valve
to pilot air distributor air cleaner at the master valve
and plug up the resulting aperture. Open indicator
valves of all cylinders and turn respective power
piston to compression TDC (with inlet and exhaust
valves closed).
Fig. 1 Starting valve (83183_0)
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Cylinder head
01.11.01
Place engine control liever in “Start” position and

slowly open shut-off valve on air receiver. If this cau-
ses air to come out through the indicator valve, this
suggests that the starting valve is leaky.
Prior to valve removal, however, check whether car-
bon deposits are the cause of the leak.
Proceed as follows:
Place engine control lever in “Stop” position. Close
shut-off valves on air receiver(s). Take down yoke
(2) and control air pipe. Remove cover (5) with pin
(3). Take out 0-seal (6). Screw bolt M6 into piston
(8) and pull piston out of cylinder (9). Clean all com-
ponents. Check that all piston rings (7) move freely.
Apply oil to piston (12). Turn valve and press down,
so any carbon will be removed from the valve seat.
Should the leak still be present, after all, remove
valve and regrind (Job Card 01.11.02).
Once the valve seat is tight, slightly apply oil to
piston (8). Install piston (8), using a cylinder (9) from
the kit of reserve parts for protecting rings (7). Fit a
new 0-seal (6). Mount cover (5) with pin (3) and
yoke (2) with domed washer. Tighten nut (1) as per
tightening instructions. Connect control air pipe (4).
Start engine several times and check that starting
valve works properly.
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Cylinder head
01.11.02
Starting valve servicing
Servicing Tools
Remove starting valve and grind. - Standard tools
- Hex. bolt M6
- Fitting device
- Socket spanner with tommy bar
- Fine grinding compound
Cross-references
- Job Card 01.05.03
Removing the valve

Put down cylinder head on wooden support.
Remove cover (5) with pin (3) and 0-seal (6). Screw
M6 bolt into piston (8) and pull piston out of head
(16).
Position fitting device (20) and socket spanner (19)
with tommy bar (Fig. 3). Retain valve (18) on tulip.
Carefully unscrew hex. nut (10) and subsequently
hex. nut (15) from valve stem (18).
Caution!
Nuts (10) and (15) are springloaded!
Remove valve (18) downwards, washer (11), piston

(12) and spring (17) upwards out of head (16).
Cleaning and inspecting the valve
Clean all components in gas oil and inspect for
wear, especially pistons (8) and (12), piston rings (7)
and (13), cylinders (9) and (14), and valve (18).
Revew as necessary. Replace 0-seal (6) in any
case.
Grinding the valve (Fig. 2)
Securely position cylinder head (16) upside down.
Use fine grinding compound and turn valve (18) into
its seat in the head. Raise tulip from seat after every
turn.
Stop grinding once the seat face on the tulip has
become a narrow ring of dull appearance.
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Cylinder head
01.11.02
If necessary, remachine tulip and seat in head by a

mechanical grinder available from this Company.
When the job is finished, remove all traces of grin-
ding compound from the components.
Refitting the valve
Slightly apply oil to valve (18), pistons (8) and (12)
and to spring (17). Turn cylinder head (16) so com-
bustion chamber is at bottom. Install valve (18) and
support it. Put spring (17) in head down on its spring
cap and introduce piston (12) into cylinder (14). Use
a cylinder (14) from the kit of reserve parts for pro-
tecting rings (13) in this process. While compressing
spring (17) as far as it will go by fitting device (20),
screw nut (15) in place. Screw on nut (10) by
wrench (19) and secure (Fig. 3). Check that valve
(18) moves freely. Fit washer (11). Install piston (8),
using a cylinder (9) from the set of reserve parts
supplied with the engine for protecting rings (7).

Fit a new 0-seal (6). Mount cover (5) with pin (3).
Mount yoke (2) and tighten bolt (1). Start engine
several times and check starting valve for proper
operation.
Note
If it is necessary to remove a starting valve with
cylinder head in situ remove adjacent exhaust valve
cage (Job Card 01.05.03) to obtain a large enough
aperture. For valve grinding, however, head removal
is indispensable.
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Cylinder head
01.12.01
Safety valve servicing (R/S/BVM)
Servicing Tools
When servicing the cylinder head or when a safety - Standard tools
valve has become leaky, remove valve, dismantle
and, if necessary, regrind. - Fine grinding compound
Aids
- DEUTZ S1 compound
Cross-references
- Job Card 07.08.01
Note
Never try to remove a leak by increasing the valve
spring loading.
Job
Stop engine. Depressurize combustion chamber by
opening the indicator valve.
Unscrew hex. bolt (15). Screw safety valve (9) out of
distributor (11).
Release union nut (2) and adjusting screw (1).
Remove valve (4), spring (5), bushes (7) with spa-
cer (6) from casing (3).
Clean all components and inspect for wear. If
necessary, grind valve tulip on its seat in the casing
with compound. Thereafter remove all traces of
compound. Renew washer (10).
Apply oil to all components before reassembly.
Introduce valve (4), bushes (7) with spacer (6) (pro-
per location see figure) and spring (5) into casing
(3). Screw in adjusting screw (1), set pressure by
means of injector testing outfit (Job Card 07.08.01)
and lock by nut (2).
Apply S1 compound to thread of casing (3). Screw
safety valve (9) into distributor (11).
Fig. 1 Safety valve (83188_0)
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01.12.01
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Cylinder head
01.12.01
Safety valve servicing (BVM)
Servicing Tools
When servicing the cylinder head or when safety - Standard tools
valve has become leaky, remove valve, dismantle
and, if necessary, regrind. - Dog wrench
Aids
- DEUTZ S1 compound
Cross-references
- Job Card 07.08.01
Note
Never try to remedy a leak by increasing the valve
spring loading.
Job
Stop engine. Depressurize combustion chamber by
opening indicator valve. Undo grooved nut with dog
wrench. Remove locking plate (11) and joint washer
(12) (remove indicator valve cover if necessary).
Screw safety valve (9) out of distributor (14). Undo
hex. nut (2). Screw out setscrew (1). Remove valve
(4), spring (5) and labyrinth bushes (7) from casing
(3).
Clean all parts and check for wear. If necessary,
grind in valve seat ring (8) and cone of valve (4) with
fine grinding compound. Remove all traces of com-
pound from housing (3) and valve (4). Renew joint
washer. Apply oil to all components before reassem-
bly.
© 0301 0299 6472-0125 JC 01 - Page 69

Cylinder head
01.12.01

Introduce valve (4), labyrinth bushes (7) and spring
(5) into casing (3). Screw in setscrew (1), set pres-
sure by means of injector testing outfit (Job Card
07.08.01) and lock by nut (2). Apply DEUTZ S1
compound to thread of casing (3). Screw safety
valve (9) into distributor (14). Place on joint washer
(12) (renew if necessary) and locking plate (11), and
secure heat insulation with grooved nut.
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Drive mechanism
02.00.01
Safety instructions for working on the drive mechanism
Caution! Caution!
When you are working on the drive mechanism, you Make sure that no dust or sand can find its way into
must always follow the instructions given below. the crankcase.
Prior to work Following work
- Stop engine. - Before closing crankcase doors be sure all tools,
- Close shut-off valves on air bottles. rags, etc. have been removed.
- Exhaust feed air piping. - Check the condition of the door gaskets.
- Open indicator valves. - Replace any defective door gaskets.
- Open crankcase doors no sooner than 10 minu- - Before restarting the engine, turn engine over
tes after the engine has come to a standstill and with open indicator valves.
the oil circulation is interrupted. - Close indicator valves.
Wait until all oil fumes have dissipated.
During work
Before turning crankshaft:
- Check that no unauthorized persons are present.
- Check that no tools may interfero with crank-
shaft rotation and thus cause damage.
- Check that removal of single motion parts will not
put entire system out of balance.
- Check that in the case of a marine engine the
propeller shaft is disengaged or, where this is
impracticable, the propeller can turn freely.
- Check that the turning (barring) gear is properly
engaged.
- Check that turning the propellershaft will not turn
the crankshaft.
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Drive mechanism
02.00.01
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Drive mechanism
02.01.01
Drive mechanism inspection
Inspection Tools
When inspecting the crankshaft and related parts, - Standard tools
inspect cams and rollers of valve drives as well.
Cross-references
- Job Card 02.00.01, 03.06.01, 08.01.01
Job
Observe safety precautions (Job Card 02.00.01).
Feel main and big-end bearing caps to check that
they have an equal temperature.
If wires locking the bolts securing timing chest and
pump cast to the crankcase are broken, this sug-
gests that bolts have slackened.
Inspect running faces (6) of liners (1) for scores and
friction marks and recondition as required (Job Card
03.06.01).
Inspect bolts securing the flywheel.
Turn engine by barring gear and inspect camshaft
faces. Smoothen scores or seizure marks by oil
stone.
Switch on oil priming pump and check that oil
comes out from all bearings. Check that all oil lines
to the bearings are free from leaks.
Inspect timing gear train and auxiliary drive c/w oil
jets. Switch on cooling water pump and read pres-
sure from gauge. Check that linter water seals are
tight.
Pay particular attention to the degree of soiling of
the crankcase interior and whether bearing metal
and/or corrosion is present in the oil sump. If neces-
sary, have an oil analysis carried out (Job Card
08.01.01) and clean the lube system.
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Drive mechanism
02.01.01
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Drive mechanism
02.02.01
Crankweb deflection gauging
Gauging Tools
In addition to regular gaugings, check deflection - Dial gauge with extension
whenever this seems necessary. (web distance:
6/8-cyl. = 156 mm
12/16-cyl. = 254 mm)
- Mirror with handle
Cross-references
- Job Card 02.00.01
Note
Deflection values consist of:
- absolute amount of deflection, measurable by
the difference between greatest and smallest
web distance during one crankshaft rotation
- plus or minus sign as shown below.
.
Plus deflection: Distance a4 > Distance a1
Zero deflection: Distance a4 = Distance a1
Minus deflection: Distance a4 < Distance a1
Normally, gauge readings inscrease as web

distances decrease, and vice versa. Fig. 1 Plus deflection (83190_0)
Be sure to perform readings when the engine is hot,
since the values differ according to the engine tem-
perature.
Readings should not be taken when the ship is in
dock.
Fig. 2 Zero deflection (83191_0)
© 0201 0299 6473-0125 JC 02 - Page 5

Drive mechanism
02.02.01
Fig. 3 Minus deflection (83192_0)

Job
Introduce gauge (11) into marks (10) punched into
webs (12) (not between balance weights) and rotate Fig. 5 Crankweb deflection, V-type engine (83410_0)
several times in this position. Set gauge to 25/100 in
measuring positions 1 or 2.
Important
When using a mirror, check readings especially
carefully.
For taking readings, turn crankshaft counter-clock-
wise, without touching the gauge.
With piston in situ: take readings in positions 2, 3, 4,
5 and 6.
With piston removed: take readings in positions 1, 3,
4 and 5.
Fig. 4 Crankweb deflection, In-line engine (83193_0)
JC 02 - Page 6 0299 6473-0125 © 0201

Drive mechanism
02.02.01
Measuring positions as viewed from the engine’s

driving end
Measuring Crankpin position

position
1 Lowest
2 First auxiliary
3 First horizontal
4 Highest
Fig. 8 Measuring positions V-type engine (83397_0)
5 Second horizontal
6 Second auxiliary
Fig. 6 Measuring positions In-line engine (83194_0)
Fig. 7 Measuring positions In-line engine (83195_0)
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Drive mechanism
02.02.01
JC 02 - Page 8 0299 6473-0125 © 0201

Drive mechanism
02.02.01
Typical gauging sheet
Engine model
Engine serial No.
Engine hot yes/no
Engine stopped for hours

Engine preheated yes/no
Water temp. °C
Oil temp. °C
Engine cold yes/no
Marine engine: Ship loaden %
Measuring Crankpin position Reading in Throw of Cylinder No.

position
V-type engine A/B A/B A/B A/B A/B A/B A/B A/B
In-line and V-type engine 1 2 3 4 5 6 7 8
1 Lowest
2 First auxiliary
3 First horizontal
4 Highest
5 Second horizontal
6 Second auxiliary
Vertical deflection (∆ “a”)

Pos. 1 minus Pos. 4
Horizontal deflection (∆ “a”)

Pos. 3 minus Pos. 5
Crankshaft end float 0.60...0.956; max. 1.2 mm
Note
Reading declines as distance “a” grows and vice versa.
Remarks
Max. permissible deflection (∆ “a”) = difference between two crankweb positions for hot engine.
© 0201 0299 6473-0125 JC 02 - Page 9

Drive mechanism
02.02.01
No. 1 throw Remaining throws
Overhung flywheel Flywheel with pedestal bearing, or no

flywheel
+ 0.00 + 0.07 + 0.04

- 0.10 / -0.11 - 0.08 / -0.11 - 0.08 / -0.10 (In-line- / V-type-engine)
Cold engine: 0.02. - 0.04 mm lower readings.

Note
If readings exceed those above, inspect bearings
and, if necessary, realign engine.
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Drive mechanism
02.03.01
Big-end bearing preload gauging
Only for connecting rods with groove Tools

and spring!
- Feeler gauge
Cross-references
- Job Card 02.00.01, 02.05.01, 02.06.01
Gauging
Where bearing shells appear to have insufficient
preload in situ, measure the gap at one rod/cap
joint.
Note
Normally it will not be necessary to check bearing
preload, since only new bearings are fitted in new
bores and tightened according to specification.
Job
With shells properly fitted, release bolt (1) comple-
tely on one side and apply some hammer blows.
Measure the resultant gap on both sides close to the
shell backing: Gap Sk should be greater than
0.4 mm. Retighten bolt.
For releasing and retightening big-end bolts see Job
Cards 02.05.01 and 02.06.01.
Fig. 1 Gap Sk (83196_0)
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02.03.01
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Drive mechanism
02.03.02
Bearing shell spread gauging
Gauging Tools
Main and big-end bearing shells to be fitted must - Caliper gauge
have sufficient positive spread, so they will have
preload in their receiving bores.
Note Caution!
All new shells have a positive spread unless they Discard shells with negative spread.
have been improperly handled, for instance in tran- Never try to correct the spread with your own
sit. Shells as from 15 mm thickness may have a means, as this is liable to destroy the running metal/
spread = 0. backing bond or to distort the bearing.
Job
The spread is positive when - measured at room
temperature - dimension “a” is larger than “D”. Main
bearings have “D” etched in on the shell front (X in
Fig. 1), while in the case of big-end bearings it
should be measured at the cap direct.
If a used shell has a negative spread (“a” smaller
than “D”), this may suggest that the bearing has
been strained due to overheating and thus has lost
its preload.
Fig. 1 Main bearing (83197_0)
© 0201 0299 6473-0125 JC 02 - Page 13

Drive mechanism
02.03.02
Main bearing “D” Big-end bearing “D”

Nominal size ø355.0 +0.036
ø275.0 +0.032
0.000 0.000
Undersize ø356.0 +0.036 -

0.000

0.000

0.000

0.000
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Drive mechanism
02.03.03
Bearing clearence gauging
Gauging Tools
Check running clearance in all cases of doubt. - Dial gauge with magnetic support
- Timber block of about 2,000 mm length
- Feeler gauge
Cross-references
- Job Card 02.00.01
Note Measuring the main bearing clearance

Normally, the running clearance need not be chek- Measure clearance above and below shaft journal
ked, since only new and genuine DEUTZ bearings by feeler gauge or plastic materials. When wear
may be fitted in new bores and the bolts tightened limits are exceeded, never remachine shells but
according to specification. replace them.
Measuring the big-end bearing clearance (Fig. 1)
Turn respective crankpin to BDC. Fasten gauge (3)
and its support (2) to connecting rod (1). Set gauge
(3) to zero position. Raise rod by timber block and
read clearance “S” from gauge, making allowance
for 0.05 mm oil film thickness (5).
Running clearance (mm) New condition Wear limit
Main bearing 0.260 - 0.393 0.45
Big-end bearing 0.210 - 0.334 0.40
Measuring the locating bearing side clearance

(Fig. 2)
Remove timing chest cover on the engine’s LH side
and measure clearance on both sides between sli-
ding segments (6) and stop flange (7).
© 0201 0299 6473-0125 JC 02 - Page 15

Drive mechanism
02.03.03
Fig. 2 Big-end bearing (83198_0)
JC 02 - Page 16 0299 6473-0125 © 0201

Drive mechanism
02.04.01
Bearing shell (wear pattern) inspection
Cross-references
- Job Card 02.03.02, 02.03.03
- Big-end bearings also:
Job Card 02.05.01, 02.06.01
- Main bearings also:
Job Card 02.07.01, 02.08.01
Inspection
Inspection of big-end bearings is required whenever
removing pistons. If the wear pattern is unsatisfac-
tory or if deep scoring and/or embedments of for-
eign particles are discovered, inspect one main
bearing also.
Every 12,000 hours be sure to inspect one main
bearing and, if in bad shape, the rest also. The first
bearing to be inspected should be the central one,
and thereafter in laid-down sequence.
At the end of 20,000 hours always renew removed
big-end or main bearings, since they are likely to
have lost their running-in properties due to advan-
ced wear and tear at this stage.
Replacement of all bearings is due at the end of
about 40,000 hours.
Bearings to be refitted must not only be inspected
for their wear pattern, but also gauged for correct
spread (Job Card 02.03.02) and running clearance
(Job Card 02.03.03).
Depending on the number of running hours and
operating conditions, the wear pattern of bearing
shells may differ widely. In all cases of doubt, there-
fore, it will be advisable to consult a DEUTZ service-
man.
© 0201 0299 6473-0125 JC 02 - Page 17

Drive mechanism
02.04.01
JC 02 - Page 18 0299 6473-0125 © 0201

Drive mechanism
02.05.01
Big-end bearing removal, In-line engine
Tools
- Standard tools
- Timber block
- 2 shell retainers
- Rail with cap receiver
Cross-references
- Job Card 02.00.01, 02.06.01, 02.09.01,
02.16.01
Job
Remove crankcase doors on both engine sides.
Mount hydraulic tool and release the four annular
nuts (Job Card 02.16.01).
Remove tool and unscrew lower nuts with associa-
ted studs.
Turn bearing cap (2) to door opening.
Push rail (5) through aperture below cap (2) to the
opposite aperture and secure there to crankcase
(6).
Place receiver (4) on rail (5) and push against cap
(2).
Be sure pins (3) engange in stud holes. Remove
upper nuts with studs. Withdraw receiver (4) with
cap (2) from crankcase (6).
© 0201 0299 6473-0125 JC 02 - Page 19

Drive mechanism
02.05.01
Fig. 1 Big-end bearing (83200_0)

Retain top shell (9) by 2 retainers (8) in diagonal
arrangement:
Screw retainer hex. bolts (7) into stud holes.
Remove top shell (9) after withdrawing piston/rod
assembly (1) (Job Card 02.09.01) and removing
retainers (8).
Fig. 2 Big-end bearing shell (83201_0)
JC 02 - Page 20 0299 6473-0125 © 0201

Drive mechanism
02.05.01
Big-end bearing removal, V-type engine
Tools
- Standard tools
- Timber block
- 2 shell retainers
Cross-references
- Job Card 02.00.01, 02.06.01, 02.09.01,
02.16.01
Job Push rail (5) through aperture below cap (2) and
Remove crankcase doors on both engine sides. secure there to crankcase (6). Place receiver (4) on
rail (5) and push it against cap (2).
Mount hydraulic tool and release the four annular
nuts (Job Card 02.16.01). Be sure pins (3) engage in stud holes. Remove
upper nuts with studs. Withdraw receiver (4) cap (2)
Remove tool and unscrew lower nuts with associa- from crankcase (6).
ted studs.
Turn bearing cap (2) to door opening.
Remove bearing caps (LH-side caps through aper-
ture and vice versa) as follows:
A B
1
Fig. 1 Rail, old version (83428_0)
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Drive mechanism
02.05.01
Fig. 2 Rail, new version (83429_0)

Retain top shell (9) by 2 retainers (8) in diagonal
arrangement. Screw retainer hex. bolts (7) into stud
holes. Remove top shell (9) after withdrawing
piston/rod assembly (Job Card 02.09.01) removing
retainers (8).
JC 02 - Page 22 0299 6473-0125 © 0201

Drive mechanism
02.06.01
Big-end bearing refitment, In-line engine
Tools
- Standard tools
- Shell retainer
Cross-references
- Job Card 00.01.03, 02.03.01, 02.03.03,
02.04.01, 02.14.01, 02.16.01
Note Fig. 1 Overlapping dimension X of the necked-down

Inspect wear pattern of shells (Job Card 02.04.01) studs before the hydraulic tightening process. Mar-
and replace shells when in bad condition. Big-end king of big-end bearing shells “A”, connecting rod
shells with scoring or embedments due to foreign “B” and big-end bearing cap “C” by means of the
matter suggest that main bearing shells are in a corresponding cylinder no.
similar condition.
Used shells, caps and studs must always be refitted
in their original location. Bearing shells, big end and
bearing cover are marked together with their cylin-
der No. on points marked with A, B and C. Bearing-
shell markings are located on front section of both
bearing-shell halves at front end facing coupling
side. New shells must be marked like the used
ones. Top and bottom shells must always be repla-
ced as a unit.
Job
Clean crankpin, top shell (6) and big end (1) throug-
hly. Any high spots on the pin must be smoothened
with an oil stone.
Place top shell (6) (without oil groove) in big end (1)
and secure by retainer. Check that mark “A” of
shells mates with big-end marks “B” and “C” while
facing the engine driving end. Apply oil to running
faces of shell and pin, but not to shell back and
joints since this would affect heat transfer.

Reinstall piston/rod assembly (Job Card 02.14.01)
with mark “B” of big end (1) facing the crankcase
door opening on the RH engine side (see
Chapter 3.2 for designations of engine ends and
sides).
© 0201 0299 6473-0125 JC 02 - Page 23

Drive mechanism
02.06.01
Tightening instructions:
1. Press connecting rod and cap against the sur-
face of crank arm and tighten annular nuts with
tommy bar.
2. Attach two hydraulic tightening appliances cross-
wise to the necked-down studs (see Job Card
02.16.01).
3. Pretighten to a pressure of P = 250 bar and tigh-
ten round nuts by hand using a tommy bar (zero
position and/or initial hole-counting point) and
mark round nuts, if necessary.
Fig. 2 Big-end bearing (83203_0) 4. Pump to raise pressure to p = 1,000 bar and tigh-
ten round nuts using a tommy bar while counting
Slowly let down assembly on crankpin and remove holes. The torque angle must be 135 +- 15° and/
shell retainers. If removed, refit rail (11). or 3 holes +- 1 pinhole dia. Should this range of
Carfully clean bottom shell (5) and big-end cap (2). tolerance not be reached, look for failure (e.g.
Install bottom shell (5) (with oil groove) in cap (2). error of assembly, faulty material, device or pres-
Install cap in receiver (10) and push against crank- sure gauge defective and others).
pin turned to the appropriate position. Check that 5. Release pressure by turning on high-pressure
mark “C” mates with “B”. pump handwheel.
Screw in top studs (4) manually and tighten annular 6. Move both tightening devices onto the 2 remai-
nuts (3) slightly with the help of the tommy bar. ning connedting-rod bolts and repeat procedure.
Demount receiver (10) and rail (11). Screw in lower The connection is now mounted.
necked-down studs (9) manually and slightly tighten 7. Verification of axial clearance:
annular nuts (8) with tommy bar.
An axial clearance of >= 0.4 mm must be main-
Studs (4) and (9) are screwed in loosely up to stop. tained at the entire periphery between start-up
Dimension “X”, measured from nut seat to stud top, surfaces of the crank case and connecting rod
should be 73 to 75 mm (Fig. 1). for connecting rods that are attached at the crank
Tighten connecting rod bolts hydraulically. arm at one end.
Note
Measure bearing clearance (Job Card 02.03.03). If
the fit appears too loose, measure shell preload
(Job Card 02.03.01).
Refit crankcase doors.
Caution!
For running in engine see Job Card
00.01.03
JC 02 - Page 24 0299 6473-0125 © 0201

Drive mechanism
02.06.01
Big-end bearing refitment, V-type engine
Tools
- Standard tools
- Shell retainer
- Mounting plates for axial play between
connecting rods A and B (Figs. 3 and 4)
Cross-references
- Job Card 00.01.03, 02.03.01, 02.03.03,
02.04.01, 02.14.01, 02.16.01
Note Fig. 1 Overlapping dimension X of the necked-down

Inspect wear pattern of shells (Job Card 02.04.01) studs before the hydraulic tightening process. Mar-
and replace shells when in bad condition. Big-end king of big-end bearing shells “A”, connecting rod
shells with scoring or embedments due to foreign “B” and big-end bearing cap “C” by means of the
matter suggest that main bearing shells are in a corresponding cylinder no.
similar condition.
Used shells, caps and studs must always be refitted
in their original location. Bearing shells, big end and
bearing cover are marked together with their cylin-
der No. on points marked with A, B and C. Bearing-
shell markings are located on front section of both
bearing-shell halves at front end facing coupling
side. New shells must be marked like the used
ones. Top and bottom shells must always be repla-
ced as a unit.
Job
Clean crankpin, top shell (6) and big end (1) throug-
hly. Any high spots on the pin must be smoothened
with an oil stone.
Place top shell (6) (without oil groove) in big end (1)
and secure by retainer. Check that mark “A” of
shells mates with big-end marks “B” and “C” while
facing the engine driving end. Apply oil to running
faces of shell and pin, but not to shell back and
joints since this would affect heat transfer.

Reinstall piston/rod assembly (Job Card 02.14.01)
with mark “B” of big end (1) facing the crankcase
door opening on the RH engine side (see
Chapter 3.2 for designations of engine ends and
sides).
© 0201 0299 6473-0125 JC 02 - Page 25

Drive mechanism
02.06.01
Tightening instructions, cylinder row A:

1. Press connecting rod and cap against the sur-
face of crank arm and tighten annular nuts with
tommy bar.
2. Attach two hydraulic tightening appliances cross-
wise to the necked-down studs (see Job Card
02.16.01).
3. Pretighten to a pressure of P = 250 bar and tigh-
ten round nuts by hand using a tommy bar (zero
position and/or initial hole-counting point) and
mark round nuts, if necessary.
Fig. 2 Pleuellager (83203_0) 4. Pump to raise pressure to p = 1,000 bar and tigh-
ten round nuts using a tommy bar while counting
Slowly let down assembly on crankpin and remove holes. The torque angle must be 135 +- 15° and/
shell retainers. If removed, refit rail (11). or 3 holes +- 1 pinhole dia. Should this range of
Carfully clean bottom shell (5) and big-end cap (2). tolerance not be reached, look for failure (e.g.
Install bottom shell (5) (with oil groove) in cap (2). error of assembly, faulty material, device or pres-
Install cap in receiver (10) and push against crank- sure gauge defective and others).
pin turned to the appropriate position. Check that 5. Release pressure by turning on high-pressure
mark “C” mates with “B”. pump handwheel.
Screw in top studs (4) manually and tighten annular 6. Move both tightening devices onto the 2 remai-
nuts (3) slightly with the help of the tommy bar. ning connedting-rod bolts and repeat procedure.
Demount receiver (10) and rail (11). Screw in lower The connection is now mounted.
necked-down studs (9) manually and slightly tighten 7. Verification of axial clearance:
annular nuts (8) with tommy bar.
For verification check alignment rod to cap at the
Studs (4) and (9) are screwed in loosely up to stop. start-up surface with the help of a ruler or a depth
Dimension “X”, measured from nut seat to stud top, gauge.
should be 73 to 75 mm (Fig. 1).
Tighten connecting rod bolts hydraulically.
JC 02 - Page 26 0299 6473-0125 © 0201

Drive mechanism
02.06.01
Tightening instructions, cylinder row B: Note

1. Turn the crankshaft into the new mounting posi- Measure bearing clearance (Job Card 02.03.03). If
tion. the fit appears too loose, measure shell preload
2. Press connecting rod A against the side face. (Job Card 02.03.01).
3. Insert connecting rod B. Refit crankcase doors.
4. Press connecting rod B against the side face. Caution!
5. Check the axial play between connecting rods A For running in engine see Job Card
and B using selected mounting plate (12), inser- 00.01.03
ting the largest possible mounting plate up to the
crankshaft journal.
Note
- The mounting plate must not protrude into the
area of the cover.
- For initial installation, an axial play of
>= 0,8 mm is required.
6. Place cover of rod B in position and tighten
round nuts slightly with tommy bar, placing
against surface.
7. Insert the 2nd mounting plate (13) of the same
thickness between cover and connecting rod A.
Tighten round nuts firmly.
8. Procedure as for row A, sections 2. to 6.
9. Remove mounting plates.
The installation procedure applies by analogy when
the connecting rod of cylinder row B is installed prior
to A.
Fig. 3 Mounting plates (83411_0)
Fig. 4 Mounting plates (83412_0)
© 0201 0299 6473-0125 JC 02 - Page 27

Drive mechanism
02.06.01
JC 02 - Page 28 0299 6473-0125 © 0201

Drive mechanism
02.07.01
Main bearing removal
Tools Aids
- Standard tools - Heat conducting compound DEUTZ P1
- Four hex. bolts M 16 x 30
Cross-references
- Bearing cap lowering device
- Job Card 02.00.01, 02.04.01, 02.08.01,
- Spreader 02.16.03
- Shell removing pin
Note
Prior to bearing removal make sure that cylinder No.
marks are provided on caps and shells (front) and
face the engine end.
To prevent crankshaft sagging, remove only every
second bearing at a time. When removing the bea-
ring next to flywheel, support the latter.
Job
Preparations for releasing nuts (8)
Remove pipe between oil gallery and bearing cap
(10). Blank off all open pipe connection to keep dirt
out.
Release central bolt (20) of socket (21) for main
bearing overtemperature alarm, pull socket upwards
and attach to crankcase, e.g. by wire (Fig. 2).
Protect plug (22) from oil that may be dripping
down. Unscrew waisted hex. bolts (6) on both Fig. 1 Main bearing (83204_0)
engine sides.
© 0201 0299 6473-0125 JC 02 - Page 29

Drive mechanism
02.07.01
Fig. 2 Main bearing overtemperature alarm

(83205_0) Fig. 3 Lowering device (83206_0)
If necessary, fit spreader (3) between cap (10) and

crankcase (2) and pressurize by pump with about
200 bar until spacer (4) drops down (Fig. 1).
Mount cap lowering device (16) to crankcase (2) on
both sides. Secure plates (14) of the device with
hex. bolts M 16 x 30 to cap (10) (Fig. 3)
Releasing nuts (8), see Job Card 02.16.03.
Removing the bearing shells (12) and (11)
Operate ratchets (15) of lowering device (16) on
both engine sides as evenly as possible to let down
cap (10) into oil sump (13).
Make sure that the relevant cylinder No. marking is
provided on the front of shell (12) facing the
engine’s driving end and remove lower shell (12). If
upper shell (11) is too hard to remove by hand,
insert pin (17) into the oil passage of crankshaft (1)
and turn shaft in the direction shown until the pin
spotfacing contact shell (11). Then turn out shell Fig. 4 Shell removing pin (83207_0)
carefully without deforming it. Make sure that the
marking is present on the front facing the engine’s
driving end. Remove shell removing pin (17) and
blank off oil passage in crankshaft to keep out dirt.
Note
Be sure to use visible blanking material, so you will
not overlook it in refitment.
For inspecting shells, see Job Card 02.04.01.
JC 02 - Page 30 0299 6473-0125 © 0201

Drive mechanism
02.08.01
Main bearing refitment
Tools Aids
- Standard tools - Locking compound DEUTZ DW 57
- Four hex. bolts M 16 x 30 - Steel wire Dr 1 DIN 177
- Bearing cap lowering device
Cross-references
- Spreader
- Job Card 02.03.03, 02.04.01, 02.16.03
- Shell removing pin
- Feeler gauge
Note Caution!
Inspect used shells (Job Card 02.04.01) and, when Pins (17) of in-line and V-type engine may
in good shape, refit them in their original location as not be interchanged.
marked. (Unlike lower shell (12), upper shell (11) is
provided with a full-length oil groove). New bearing
shells are to be installed without any correction (e.g.
bedding-in) and marked.
Marking will begin with 1 on 1st bearing at front end
of both bearing halves:
- on in-line engines at exhaust end
- on V-type engines on cylinder bank A
always at front end facing coupling side.
Bearing cover marked at front end facing coupling
side and beginning with 1 at coupling end. In situ
this mark is found on the right-hand engine side
mating the mark on the crankcase. Inspect shaft
journal and, if necessary. smoothen by oil stone.
Job
Refitting the bearing shells (11) and (12)
Carefully clean all components. Remove blanketing
from hole to oil passage in crankshaft (1). Slightly
apply some lube oil to shaft journal and shell run-
ning surface, but keep shell back and seat perfectly
dry.
Should it be found impossible to install upper shell
(11) (provided with oil groove) without any aid, pro-
ceed as follows:
Introduce pin (17) into oil passage of crankshaft (1)
and turn crankshaft (1) and turn crankshaft until pin
is in the position as shown in Fig. 1.
Fig. 1 Detail X (83208_0)
© 0201 0299 6473-0125 JC 02 - Page 31

Drive mechanism
02.08.01
Install top shell (11) in cap (10) (mark facing driving

end) and raise both by lowering device (16) (Fig. 2)
up to journal, and slightly tighten with two nuts (5).
Then turn into place by turning crankshaft. Cap (10)
is radially located in crankcase (2) by two pins (19),
while the axial location of shell and cap is provided
by plates (18) fitted at each front.
Screw one anular nut (8) in place on each bearing
side and turn shaft slowly as shown until shell (11) is
properly seated in crankcase (2).
Lower cap (10) again into oil sump, remove pin (17)
and install bottom shell (12) (without oil groove) in
cap (10) with mark facing the engine’s driving end.
Raise cap (10) tight with crankcase (2), apply lube
oil to studs (7), check that nuts (8) turn freely over
the entire stud thread, fit spacers (9) and screw nuts
in place and tighten by hydraulic tool (Job Card
02.16.03).
Fit spacers (4) (Fig. 2), screw in hex bolts (6) and
tighten as per tightening instructions. Fig. 3 Main bearing (83204_0)
When fitting new bearing shells, check running clea- Clean plug (22) for bearing overtemperature alarm
rance (Job Card 02.03.03.). from any oil film. Connect socket (21) to plug (22)
(observe correct location), secure by central bolt
(20) and tighten by hand (paying attention to bore
position. Secure central bolt with a Dr 1 DIN 177
steel wire (Fig. 5).
Remove plugs from oil gallery and bearing cap,
exercizing utmost cleanliness. Connect oil line bet-
ween gallery and cap. Attach crankcase door.
Caution!
For running in engine see Job Card 00.01.03
Fig. 2 Lowering device (83206_0)

(83205_0)
JC 02 - Page 32 0299 6473-0125 © 0201

Drive mechanism
02.08.01

(83209_0)
Note
Should removal of bearing caps require studs (7.1)
and (7.2) to be removed or replaced, apply DEUTZ
DW 57 locking compound to threads.
© 0201 0299 6473-0125 JC 02 - Page 33

Drive mechanism
02.08.01
JC 02 - Page 34 0299 6473-0125 © 0201

Drive mechanism
02.09.01
Piston removal, without scraper ring
When you replace a piston or the piston rings, you Tools

also have to replace the cylinder liner if its wear
limits have been exceeded. Cylinder liners still - Standard tools
dimensionally correct must be rehoned. Call the - Hoist
DEUTZ Service staff to perform the honing jobs.
- Tap M 16
- Piston suspension device
- Liner retainer
Cross-references
- Job Card 01.04.01, 02.05.01, 03.03.01
Job
Remove cylinder head (Job Card 01.04.01) and big-
end cap (Job Card 02.05.01). Secure top bearing
shell. Turn up piston (6) until brigth liner running sur-
face is just blanked off by piston top edge. Close
gap between piston top and liner (5) and then
scrape off carbon from liner top section.
Inspect reversing mark of top ring; if this mark has
become so deep that rings may catch here in the
process of piston removal, grind mark away (Job
Card 03.03.01).
Turn up piston (6) to TDC. Clean tapholes M 16 by
tap in piston top and mount device (1). Put liner
retainer (3) on two opposite studs (4) and modera-
tely tighten with two annular nuts (2). Withdraw
piston/rod assembly carefully out of liner (5). To pre-
vent the liner being damaged in this process, use
handle (9) for piston guidance (V-type engine) and
have a second man holding big end (8).
Fig. 1 Removal, In-line engine (83210_0)
© 0201 0299 6473-0125 JC 02 - Page 35

Drive mechanism
02.09.01
Fig. 2 Removal, V-type engine (83413_0)
Fig. 3 Piston (83211_0)

Put down piston/rod assembly in a wooden rack (7).
On ships secure rod against rocking.
Wrap adhesive tape or oil paper around crankpin to
protect it from dirt or damage.
JC 02 - Page 36 0299 6473-0125 © 0201

Drive mechanism
02.09.01
Piston removal, with scraper ring
When you replace a piston or the piston rings, you Tools

also have to replace the cylinder liner if its wear
limits have been exceeded. Cylinder liners still - Standard tools
dimensionally correct must be rehoned. Call the - Removal tool for scraper ring
DEUTZ Service staff to perform the honing jobs.
- Hoist
- Tap M 16
- Liner retainer
Cross-references
- Job Card 01.04.01, 02.05.01, 03.03.01
Job Hold down cylinder liner (5) with device (3). Turn
Remove cylinder head (Job Card 01.04.01) and big- piston slowly upwards, and press out scraper ring
end cap (Job Card 02.05.01). Secure top bearing (13).
shell. In case of wear and tear or damage, the scraper
At scraper ring (13), clean the three notches for fit- ring must be replaced. Close gap between piston
ting the removal device (12). top and liner (5) and then scrape off carbon from
liner top section.
Fit removal device (12) at scraper ring (13).
12 13
Fig. 1 Scraper ring (83458_0)
© 0201 0299 6473-0125 JC 02 - Page 37

Drive mechanism
02.09.01
Inspect reversing mark of top ring; if this mark has

become so deep that rings may catch here in the
process of piston removal, grind mark away (Job
Card 03.03.01).
Turn up piston (6) to TDC. Clean tapholes M 16 by
tap in piston top and mount device (1). Put liner
retainer (3) on two opposite studs (4) and modera-
tely tighten with two annular nuts (2). Withdraw
piston/rod assembly carefully out of liner (5). To pre-
vent the liner being damaged in this process, use
handle (9) for piston guidance (V-type engine) and
have a second man holding big end (8).
Fig. 3 Removal, V-type engine (83460_0)
Fig. 2 Removal, In-line engine (83459_0)
Fig. 4 Piston (83211_0)

Put down piston/rod assembly in a wooden rack (7).
On ships secure rod against rocking.
Wrap adhesive tape or oil paper around crankpin to
protect it from dirt or damage.
JC 02 - Page 38 0299 6473-0125 © 0201

Drive mechanism
02.10.01
Piston inspection/servicing
Tools
- Piston ring spreader
- Ground piston ring fragment of 100 mm
length
- Fine emery cloth, No. 250
- Carborundum
Cross-references
- Job Card 01.04.01, 02.01.01, 02.04.01,
02.09.01, 02.10.01, 02.10.02,
02.10.04, 03.03.01
Note No further pistons need be drawn if this initial

Your engine’s operating hours figure up to the time inspection reveals that
at which all pistons have to be removed for the first - the running surfaces of all liners are free from
time is used as the maintenance interval for pressure marks, scores or other defects (Job
pistons in the context of “Scheduled Maintenance”; Card 02.01.01);
enter this maintenance interval in your maintenance - the drawn piston is in good shape (Job Card
interval schedule. 02.10.04);
Inspection - the rings of the drawn piston are also in good
Piston servicing intervals are not specidied in the shape, i. e. moving freely in their grooves and
Maintenance Schedule since they largely depend not unduly worn:
on engine application and loading as well as on fuel l Top layer fully intact (without signs of crumbling)
and lube oil qualities. For locally fixing a reasinable
interval, the following procedure is recommended: l Absence of sharp edges
When the first inspection is due, inspect all cylinder l Chromium-plated ring: plating fully intact
liners from below (unless heads have been remo- l Oil control ring: the two running edges not
ved by Job Card 01.04.01) and draw only the piston exceeding 1 mm in height.
(Job Card 02.09.01) of that liner which appears to
be in the worst shape. No further pistons need be
drawn if this initial inspection reveals that:
© 0201 0299 6473-0125 JC 02 - Page 39

Drive mechanism
02.10.01
The same goes for the next inspections as specified

in the Maintenance Schedule (Summarized Opera-
ting Instructions).
For enhanced safety, it is advisable also to inspect
all other liners from below.
However, should the deposits in the piston cooling
area be found to exceed 0.5 mm, dismantle the
piston in order to clean the inside spaces.
In the case of depositis >= 3 mm, inspect the piston
for any subsequent damage.
On the combustion chamber side, measure the
layer of deposits at the piston crown centre relative
to ist edge.
In clean condition of the contour on the combustion
chamber side, the piston crown centre should be
deeper by 1 +- 0.1 mm relative to the edge.
Should the drawn piston exhibit defects such as
those described, be sure to draw all pistons and ser- Fig. 1 Piston ring spreader (83212_0)
vice them as per the instructions of this card.
Servicing
Note
Be sure to renew all rings of a drawn piston. Refit-
ting of a used ring is permissible only when is has
run less than 1,000 hours and is in a perfect shape.
Job
Remove piston rings by means of spreader (1) only.
Free piston from carbon. Likewise clean grooves,
and piston cooling channel, using a ring fragment
for scraper. Because of the chamfered face, scrape
with the ring inside and be sure not to damage the
grooves. Smoothen minor friction and seizure marks
by fine carborundum. In the case of heavy scoring
or other defects, replace piston. Before refitting a
used piston, guage the ring grooves (Job Card
02.10.02).
Fit piston rings, agian using spreader (1).
Note
After piston removal, inspect big-end bearings (Job
Card 02.04.01).
JC 02 - Page 40 0299 6473-0125 © 0201

Drive mechanism
02.10.02
Piston ring/groove gauging
Inspection Tools
Whenever a piston has been removed, measure the - Feeler gauge
ring grooves.
- Piston ring pliers
Note
Use only tools in perfect condition.
Job
Gauge clearance “S” between new ring and bottom
flank of groove at four locations offset through 90°.
In doing so, push ring into groove as far as it will go
and mark depth determined on gauge.
Fig. 1 Gauge clearance (83213_0)

If at any of the four locations the gauge can be
inserted up approx. 6 mm or more of the total depth,
the wear limit is exceeded.
© 0201 0299 6473-0125 JC 02 - Page 41

Drive mechanism
02.10.02
Dimensions specified for piston rings and grooves
New condition Wear limit S 1)

Dimensions Minimum clearance -
Maximum clearance
Groove 1 8.20 - 8.22 0.263 - 0.298 0.8 2)

Ring 1 7.922 - 7.937
Groove 2 8.20 - 8.22 0.213 - 0.248 0.8 2)

Ring 2 7.972 - 7.987
Groove 3 and 4 8.05 - 8.07 0.063 -0.098 0.8

Ring 3 and 4 7.972 - 7.987
Groove 5 10.04 - 10.06 0.053 - 0.095 0.8

Ring 5 9.965 - 9.987
1) Be sure this limit is not exceeded during the next

maintenance interval, taking into account that
wear is progressive, i.e., the greater the clea-
rance, the quicker the rate of wear.
2) Should it be expected that, during the next
maintenance interval, this wear of S = 0.8 mm
would be exceeded, the piston must be sent to
our headquarters for reconditioning.
Use only genuine DEUTZ rings!
1. Compression Ring
Chromium-plated-“GOECRO NB TOP” (Mark “Top”
to be at top)
2. Compression Ring
Chromium-plated tapered compression ring “GOE-
CRO NB 3” (Mark “Top” to be at top)
3. Same as 2.
4. Same as 2.
5. Oil control Ring
Double-chamfered springloaded oil control ring, Fig. 2 Piston rings (83214_0)
chromium-plated.
JC 02 - Page 42 0299 6473-0125 © 0201

Drive mechanism
02.10.04
Piston reconditioning
It is normally not necessary to dismantle the two- - Standard tools
piece piston for replacing 0-seal (2). If, however, dis-
mantling is indispensable, for instance because the
ring grooves must be enlarged, proceed as descri- Aids
bed below. - DEUTZ S2 compound
Cross-references
- Job Card 02.10.01, 02.10.02
Note
Piston inspection and servicing see Job Card
02.10.01, piston rings and grooves see Job Card
02.10.02. Remachining of the piston ring grooves
and fitting of oversize rings is not permissible in the
case of composite piston.
Job
After cleaning and gauging pistons, unscrew bolts
(4) and take out along with the thrust piece (5).
Separate piston top (1) from base (3).
Caution!
Do not damage joint faces!
Take down 0-seal (2). Clean coolant passages,
inlets and outlets in top and base for deposits.
Caution!
No manual or mechanical work is permissi-
ble on joint faces between top (1) and base
(3) or on centering faces.
Fig. 1 Piston (83215_0)
© 0201 0299 6473-0125 JC 02 - Page 43

Drive mechanism
02.10.04
Install new 0-seals (2) and apply high-temperature

grease (which will protect the seal when assembling
the piston). Clean all joint faces carefully.
Put piston top (1) on its base (3) with dowel pin (6)
properly engaged.
Apply DEUTZ S2 to thread and head bottom of bolts
(4) and introduce jointly with thrust piece (5). Screw
in bolts, tighten them through 130 Nm, release, and
retighten through 130 Nm.
JC 02 - Page 44 0299 6473-0125 © 0201

Drive mechanism
02.12.01
Piston pin removal/refitment
Tools
- Circlip pliers
- Hoist
Cross-references
- Job Card 02.09.01, 02.13.01
Note
Remove piston (Job Card 02.09.01). Prior to remo-
ving gudgeon pin check, wether markings are pre-
sent on piston, connecting rod shank and big-end
bearing cover with cylinder No. (point I, II and III) as
per Figure 1. After pin removal, measure pin and
bush (Job Card 02.13.01).
Removing the pin
Attach connecting rod to hoist with piston (1) han-
ging down. Remove circlips (3) and push out pin (2).
If necessary, warm up piston skirt with hot-air blo-
wer.
Clean piston pin, bush and receiving bore.
Refitting the piston
Install one circlip (3). Attach connecting rod to hoist
so that pin bush is in line with the bore in the piston.
Assemble piston and connecting rod according to
markings (Figure 1). Markings I and II must be tur- Fig. 1 Piston with connecting rod (83216_0)
ned by 180 deg. as compared with piston marking I.
Caution!
Insert piston together with connecting rod into
When turning upside down, be sure the big
engine in such a way that piston marking I is placed
end will not strike the piston.
at timing side.
Fig. 1: Marking position of piston I, connecting rod
Consequently, big-end bearing covers must always
shank II and big-end bearing cover III.
be mounted from exhaust end on in-line engines.
Apply oil to pin and bush. Install pin and fit second
circlip.
© 0201 0299 6473-0125 JC 02 - Page 45

Drive mechanism
02.12.01
Fig. 2 Piston (83217_0)
JC 02 - Page 46 0299 6473-0125 © 0201

Drive mechanism
02.13.01
Piston pin bush gauging/reconditioning
Gauging Tools
Measure the bearing clearance. - Feeler gauge
- Inside micrometer
- Outside micrometer
Cross-references
- Job Card 02.12.01
Note
A replacement of the bush requires piston/rod align-
ment, so the job should be entrusted to a DEUTZ
serviceman.
Job
Remove pin (Job Card 02.12.01). Put rod (2)
upright. Introduce cleaned pin (1) into cleaned bush
until pin projection “a” is equal at both bush ends.
Measure bearing clearance “S” by feeler gauge.
When the specidied wear limit has been exceeded,
the components must be individually gauged and
the worn items replaced.
Clearance New Condition Wear Limit
Pin/bush 0.19-0.242 0.39

Pin 0.0-0.034 0.07
piston bore
Dimension
Bush bore 160.19+0.04 160.36

(installed)
Pin diameter 160-0.012 159.97
Bore in piston 160+0.022 160.04
© 0201 0299 6473-0125 JC 02 - Page 47

Drive mechanism
02.13.01
Reconditioning
Press out old bush with a suitable tool after applying
a saw. Undercool new bush to -60 °C. Heat small
end in oil bath to 80 - 90 °C. Introduce bush so that
it agrees with the contours of the small-end bore.
Check bush for roundness and then check - with the
adjoining fixture (4) - that the unparallelism between
the small-end/big-end bearing centre lines is
max. 0.04 mm per 100 mm length.
Where no such fixture is available, proceed as fol-
lows:
Remove rings from piston. Install piston. Fit big-end
bearing. Introduce a feeler gauge between piston
and liner and check that clearances endwise and
crosswise to the engine are identical. Fig. 1 Piston pin bush (83218_0)
Failing the above, replace rod. Never try to straigh-
ten it locally.
Fig. 2 Connecting rod (83219)
JC 02 - Page 48 0299 6473-0125 © 0201

Drive mechanism
02.14.01
Piston refitment, without scraper ring
Tools
- Standard tools
- Hoist
- Piston ring compressor
- Piston ring pliers
- Bearing shell retainers
Cross-references
- Job Card 00.01.03, 01.09.01, 02.05.01,
02.06.01, 02.10.01, 02.10.02,
02.12.01, 03.02.01
Note Tighten turnbuckles (6) (Fig. 3), while beating com-

Prior to piston fitment, inspect, service and gauge pressor with your bare hands to ensure square sea-
pistons and rings (Job Card 02.10.01 and 02.10.02). ting of ring.
Mark piston with cylinder No. (CN) as per Figure 2. This patting with your hands is necessary to ensure
Inspect liner (Job Card 03.02.01) and roughen. See that the piston rings lie evenly in the taut-band, and
also description of piston rings and grooves (Job to make sure that the piston rings come to rest in
Card 02.10.02). the piston ring grooves without jamming.
Caution!
If piston has been detached from rod, reas-
semble (Job Card 02.12.01).
Job, In-line engine (Fig. 1 to 4)
Mount suspension device (1) on piston (4). Fit rings
by special pliers, startin gwith the bottom ring.
Check that spring gab of oil control rings is offset
through 180° to ring gap.
Distribute ring gaps around piston (Fig. 2).
Apply an ample amount of lube oil to piston and
rings.
Slip completely unloaded compressor (2) over rings
until the top ends of the three strips (5) (Fig. 3) are
squarely seated on the piston top. Be sure no ring
gap will be situated within the gap of compressor
(2).
Fig. 1 Piston refitment, In-line engine (83220_0)
© 0201 0299 6473-0125 JC 02 - Page 49

Drive mechanism
02.14.01
Release turnbuckles (6) through two turns.

Turn crankpin of respective cylinder to TDC and
farther through some 30° towards engine side
mounting exhaust manifold.
Generously lubricate liner and crankpin. Install top
bearing shell into big end and secure by retainer.
Lower piston (4) with conrod by hoist into liner (3),
while taking care of mounting position (Fig. 2),
seeing to it that the big end will not damage the liner
bore. Check that big end and shell marks point to
the exhaust side.
Lower piston (4) farther until the bottom edge of
compressor (2) will be introduced into chamfered
Fig. 2 Ring gap position (83221_0)
liner (3), so lower ends of three compressor strips
Fig. 2 Marking a piston and ring gap position: (5) will be squarely seated on liner flange (Fig. 4).
R1 - R5: ring 1 - ring 5 Lower piston farther down and press big end
CN: Cylinder-No. against crankpin.
Y: Timing side Remove suspension device (1), compressor (2) and
shell retainers. Fit big-end bearing (Job Card
02.06.01).
Caution!
00.01.03
Fig. 3 Compressor strips (83222_0)
JC 02 - Page 50 0299 6473-0125 © 0201

Drive mechanism
02.14.01
Job, V-type engine (Fig. 5 to 8)

by special pliers, starting with the bottom ring. Distri-
bute ring gaps. Check that spring gap of oil control
rings is offset through 180° to ring gap.
Distribute ring gaps around piston (Fig. 6). Apply an
ample amount of lube oil to piston and rings.
(2).
Tighten turnbuckles (6) (Fig. 7), while beating com-
pressor with your bare hands to ensure square sea-
ting of ring. Fig. 6 Marking a piston and ring gap position:
R1 - R5: ring 1 - ring 5
CN: Cylinder-No.
Y: Timing side
Fig. 5 Piston refitment, V-type engine (83414_0)
Fig. 8 Compressor strips, V-type engine (83415_0)
© 0201 0299 6473-0125 JC 02 - Page 51

Drive mechanism
02.14.01

Turn the crankpin of respective cylinder to TDC.
Remove cover from piston pin. Generously lubricate
liner, piston and crankpin. Install top bearing shell
into big end and secure by retainer.
Lower piston (4) with connecting rod by hoist into
liner (3), while taking care of mounting postion
(Fig. 6). Guide piston with lever (7) so that big end
will not damage the liner bore.
Lower piston farther until the bottom edge of com-
pressor (2) will be introduced into chamfered liner
(3), so lower ends of three compressor strips (5) will
be squarely seated on liner flange (Fig. 8).
The connecting rods of the A-side are mounted from
the B-side, and vice versa.
Check that big end and shell marks point to the
engine driving end. Lower piston farther down until
big end rests on crankpin. Remove suspension
device (1), compressor (2) and shell retainers. Fit
big end bearing (Job Card 02.06.01).
Caution!
00.01.03
JC 02 - Page 52 0299 6473-0125 © 0201

Drive mechanism
02.14.01
Piston refitment, with scraper ring
Tools Aids
- Standard tools - Compound DEUTZ S1
- Hoist
Cross-references
- Job Card 00.01.03, 01.09.01, 02.05.01,
- Piston ring compressor 02.06.01, 02.10.01, 02.10.02,
- Piston ring pliers 02.12.01, 03.02.01
- Bearing shell retainers
- Piston installation ring
Note Tighten turnbuckles (6) (Fig. 3), while beating com-

Prior to piston fitment, inspect, service and gauge pressor with your bare hands to ensure square sea-
pistons and rings (Job Card 02.10.01 and 02.10.02). ting of ring.
Mark piston with cylinder No. (CN) as per Figure 2.
Inspect liner (Job Card 03.02.01) and roughen. See
also description of piston rings and grooves (Job
Card 02.10.02).
Caution!
If piston has been detached from rod, reas-
semble (Job Card 02.12.01).
Job, In-line engine (Fig. 1 to 4)
by special pliers, startin gwith the bottom ring.
Check that spring gab of oil control rings is offset
through 180° to ring gap.
Distribute ring gaps around piston (Fig. 2).
Apply an ample amount of lube oil to piston and
rings.
Fig. 1 Piston refitment, In-line engine (83465_0)
(2).
© 0201 0299 6473-0125 JC 02 - Page 53

Drive mechanism
02.14.01

Turn crankpin of respective cylinder to TDC and
farther through some 30° towards engine side
mounting exhaust manifold.
Generously lubricate liner and crankpin. Install top
bearing shell into big end and secure by retainer.
Insert piston installation ring (8) in cylinder liner (3)
with the installation bevel facing upwards.
Use lifting tackle to lower piston (4) and connecting-
rod into cylinder liner (3) via piston installation ring
(8), making sure that everything is in the correct
configuration (Fig. 2), seeing to it that the big end
will not damage the liner bore. Check that big end
and shell marks point to the exhaust side.
Fig. 2 Marking a piston and ring gap position:
Lower piston (4) farther until the bottom edge of
R1 - R5: ring 1 - ring 5 compressor (2) will be introduced into chamfered
CN: Cylinder-No. liner (3), so lower ends of three compressor strips
(5) will be squarely seated on liner flange (Fig. 4).
Y: Timing side
Lower piston farther down and press big end
against crankpin.
Remove suspension device (1), compressor (2) and
shell retainers.
Take off piston installation ring (8) upwards.
Coat the outer surface of scraper ring (9) with
mounting agent DEUTZ S1, and insert in cylinder
liner (3).
Fit big-end bearing (Job Card 02.06.01).
Caution!
00.01.03
JC 02 - Page 54 0299 6473-0125 © 0201

Drive mechanism
02.14.01
Job, V-type engine (Fig. 5 to 8)

by special pliers, starting with the bottom ring. Distri-
bute ring gaps. Check that spring gap of oil control
rings is offset through 180° to ring gap.
Distribute ring gaps around piston (Fig. 6). Apply an
ample amount of lube oil to piston and rings.
(2).
Tighten turnbuckles (6) (Fig. 7), while beating com-
pressor with your bare hands to ensure square sea-
ting of ring. Fig. 6 Marking a piston and ring gap position:
R1 - R5: ring 1 - ring 5
CN: Cylinder-No.
Y: Timing side
Fig. 5 Piston refitment, V-type engine (83463_0)
Fig. 8 Compressor strips, V-type engine (83464_0)
© 0201 0299 6473-0125 JC 02 - Page 55

Drive mechanism
02.14.01

Turn the crankpin of respective cylinder to TDC.
Remove cover from piston pin. Generously lubricate
liner, piston and crankpin. Install top bearing shell
into big end and secure by retainer.
Insert piston installation ring (8) in cylinder liner (3)
with the installation bevel facing upwards.
Use lifting tackle to lower piston (4) and connecting-
rod into cylinder liner (3) via piston installation ring
(8), making sure that everything is in the correct
configuration (Fig. 6). Guide piston with lever (7) so
that big end will not damage the liner bore.
Lower piston farther until the bottom edge of com-
pressor (2) will be introduced into chamfered liner
(3), so lower ends of three compressor strips (5) will
be squarely seated on liner flange (Fig. 8).
The connecting rods of the A-side are mounted from
the B-side, and vice versa.
Fig. 9 Scraper ring (83462_0)
Check that big end and shell marks point to the
engine driving end. Lower piston farther down until
big end rests on crankpin. Remove suspension
device (1), compressor (2) and shell retainers.
Take off piston installation ring (8) upwards.
Coat the outer surface of scraper ring (9) with
mounting agent DEUTZ S1, and insert in cylinder
liner (3).
Fit big-end bearing (Job Card 02.06.01).
Caution!
For running in engine see Job Card 00.01.03
JC 02 - Page 56 0299 6473-0125 © 0201

Drive mechanism
02.16.01
Handling the 135-mm-diameter hydraulic clamping device
Note Tools
The 135-mm-diameter hydraulic clamping device is - Hydraulic clamping device, 135 mm in
use to tighten the round nuts of cylinder heads, con- diameter, with threaded bush, spacer
necting rod bearing caps, and engine foundations tube and puller bolt
(where provided). Threaded bushes, spacer tubes
and puller bolts are provided in the correct sizes for - Tommy bar
bolting the connecting rod bearing caps and the - Wrench
foundation. For the cylinder head, the puller bolt has
been designed so as to dispense with the need for a - High-pressure pump with pressure gau-
threaded bush. ge
Legend for Fig. 2, 3 and 4: - High-pressure hoses with distributor
a = unstressed anti-fatigue stud bolt - Feeler gauge
b = stressed anti-fatigue stud bolt
Cross-references
- Job Card 01.04.01, 01.09.01, 02.16.02
Job Caution!
See Job Card 02.16.02 for how to fill and bleed the Washers (11) are placed only under the
hydraulic clamping device. cylinder head round nuts 5 - 8, and not on
the valve lifter axles under cylinder head
round nuts 1 - 4.

Cylinder head (Figs. 1 and 2)
The eight cylinder round nuts must be loosened or
tightened in two groups: first the round nuts 1 - 4
simultaneously, and then the round nuts 5 - 8 simul-
taneously (Fig. 1), using for hydraulic clamping
devices in each case (Fig. 2).
Loosening procedure
When loosening the round nuts, record the loose-
ning pressure. For that, from a pressure of 800 bar,
raise the pressure in steps of 50 bar. After each step
check, if round nuts can be loosened.
See Job Card 01.04.01 for how to remove the cylin-
der head. Fig. 2 Hydraulic clamping device (83416_0)
See Job Card 01.09.01 for how to fit the cylinder

head back in place.
© 0201 0299 6473-0125 JC 02 - Page 57

Drive mechanism
02.16.01
Connecting rod bearing

(Fig. 3)
Tighten the four connecting rod bearing round nuts
in pairs simultaneously in a diagonally opposite
sequence, using two hydraulic clamping devices
(Fig. 3).
See Job Card 02.05.01 for how to remove the con-
necting rod bearing.
See Job Card 02.06.01. for how to refit the connec-
ting rod bearing.
Foundation
(Fig. 4)
Use either one or two hydraulic clamping devices
(Fig. 4) as required in order to tighten the foundation
round nuts.
See Job Card 03.07.01 for how to check the founda-
tion round nuts.
Unscrewing the cylinder head round nuts (10)
Clean the contact area for the clamping device.
Screw the puller bolt (7) onto the anti-fatigue stud
bolt (8) as far as it will go. Now fit the spacer tube (5)
and the clamping device. Use the tommy bar (9) to
tighten the round nut (13). Connect a high-pressure
Fig. 3 Hydraulic clamping device (83226_1)
hose to the coupling plug (3) and the high-pressure
pump.
Be careful never to kink, sharply bend or pull the
high-pressure hoses.
Unscrewing the round nuts (10) of the connec-
ting rod bearing and the foundation
Clean the contact area for the clamping device.
Screw a threaded bush (4) of the suitable thread
diameter onto the anti-fatigue stud bolts (8) until the
dowel pin (12) abuts - note that for the collar side
must face the round nut (10), while for the connec-
ting rod it must be facing away.
Fit a spacer tube (5) of the appropriate size and the
clamping device. Connect a high-pressure hose to
the coupling plug (3) and the high-pressure pump.
Be careful never to kink, sharply bend or pull the
high-pressure hoses.
Use the wrench (6) to screw the puller bolt (7) into
the threaded bush (4) onto the protruding end of the
anti-fatigue stud bolt (8) until the piston (2) is flush
with the cylinder (1).
Fig. 4 Hydraulic clamping device (83227_1)
JC 02 - Page 58 0299 6473-0125 © 0201

Drive mechanism
02.16.01
Then screw the puller bolt (7) 1 1/2 turns back. Ope- Tighten connecting rod bearing round nuts (10) in
rate the highpressure pump until the specified oil accordance with the instructions given in Job Card
pressure for unscrewing the round nuts has been 02.06.01. Bleed off oil pressure. Use wrench (6) to
built up: unscrew the screw (7). Remove clamping device
- cylinder head round nuts p= 925+25 bar; and spacer tube (5). Push piston (2) down until it is
flush with the top edge of the cylinder (1). (This is
- connecting rod bearing round nuts p= 1000 bar; possible only when the high-pressure hose is con-
- foundation round nuts p= 1020 bar. nected to the high-pressure pump.) Disconnect the
If the round nut (10) cannot yet be unscrewed, high-pressure hoses. Unscrew threaded bush (4).
increase the oil pressure slowly by 10 - 20 bar until Tightening the cylinder head round nuts (10)
the round nut comes loose. Insert the tommy bar (9) Oil the thread of the anti-fatigue stud bolts (8) with
through the opening in spacer tube (5) in order to engine oil. Check that the round nuts (10) move
screw the round nut (10) up until it is just short of easily over the entire thread length of the anti-fati-
actual contact. gue stud bolt (8).
Guideline values for unscrewing the round nuts are: Screw on the round nuts (10) and tighten them until
approx. 12 hole spacings for the cylinder head, and they are handtight. Use a feeler gauge to check
approx. 7 - 9 hole spacings for the connecting rod. whether the round nuts are flush without a gap.
Mount the hydraulic clamping device with high-pres-
Bleed of oil-pressure.
sure pump, as described under “Unscrewing the
Then continue: cylinder head round nuts (10)”. Build up the speci-
for connecting rod bearing and foundation: fied oil pressure, and tighten round nuts (10) in
accordance with the instructions given in Job Card
Push piston (2) down until it is flush with the cylinder
01.09.01. Bleed off oil pressure. Disconnect high-
(1). Disconnect the high-pressure hose. Use wrench
pressure hoses. Use tommy bar (9) to loosen and
(6) to unscrew the screw (7). Remove the clamping
unscrew round nut (13). Remove clamping device
device and the spacer tube (5). Unscrew the
and spacer tube (5). Unscrew puller bolt (7).
threaded bush (4) and the round nut (10).
for cylinder head:
Disconnect the high-pressure hose. Use the tommy
bar (9) to loosen and unscrew the round nut (13).
Remove the clamping device and the spacer tube
(5). Unscrew the puller bolt (7) and the round nut
(10).
Tightening the connecting rod bearing and foun-
dation round nuts (10)
Oil the thread of the anti-fatigue sutd bolts (8) with
engine oil. Check that the round nut (10) moves
easily over the entire thread lenght of the anti-fati-
gue stud bolt (8).
Screw on the round nuts (10) and tighten them until
they are hand-tight. Use a feeler guage to check
whether the round nuts are flush all the way round
without a gap.
round nuts (10)”. When you do this, make sure that
the threaded bush (4) is screwed on far enough to
cause the dowel pin (12) to abut.
Build up the specified oil pressure in accordance
with the tightening instructions (see Technical Parti-
culars, and Job Cards 01.09.01 and 02.06.01).
Use the tommy bar (9) to retighten the foundation
round nuts (10) until they abut.
© 0201 0299 6473-0125 JC 02 - Page 59

Drive mechanism
02.16.01
Checking the round nuts after tightening

Note
This check must be performed after the specified
number of engine operating hours, or if there is a
suspicion that the round nuts may have come loose.
round nuts (10)”.
Build up the oil pressure for the
- cylinder head round nuts p= 925+25 bar;
- connecting rod bearing nuts p= 1000 bar;
- foundation round nuts p= 1020 bar.
It must now be just possible to loosen the round nut
(10) you are checking with the tommy bar (9). If this
is not the case, you must retighten the roundnut
again (see under “Tightening the round nuts”).
Note
When replacing the pressure gauge at the high-
pressure pump, make sure that you do not lose the
restrictor insert with restrictor duct, steel ball and
compression spring, and that these are fitted back in
place before you screw on a new pressure gauge.
JC 02 - Page 60 0299 6473-0125 © 0201

Drive mechanism
02.16.02
Hydraulic tool for annular nuts servicing
Cross-references
- Job Card 02.16.01, 02.16.03
Servicing
(Filling and bleeding)
Note
Although satisfactory operation of this equipment
requires complete freedom from air in piping etc.,
specific bleeding is normally not required since the
automatic couplings keep oil in and air out.
For tool handling see Job Cards 02.16.01 and
02.16.03.
1 Pump
2 Oil reservoir
3 Filler plug Fig. 1 Pump (83228_0)
4 Hand lever
5 Retaining spring
6 Hand wheel for shut-off valve
7 Pressure gauge
8 Hose
9 Distributor
10 Safety half-coupling
11 Ram cylinder
12 Safety half-coupling Fig. 2 Hydraulics (83229_0)
13 Bleeder plug
Caution!
Pressurized but not connected hoses must
be closed by nipple (14).
© 0201 0299 6473-0125 JC 02 - Page 61

Drive mechanism
02.16.02
Any other oils are liable to affect sealing materials.

Definitely unsuitable are brake fluids, dashot oils,
gas oil, kerosene or gasoline/petrol.
From time to time, filter the oil, at the same time rin-
sing the reservoir.
Job
Fill pump (1) in horizontal position though hole (3) of
reservoir (2) with min. 1.5 litres of oil. Connect pump
(1), support for gauge (7), distributor (9) and rams
(11) to hoses. Release bleed plug (13) of ram (11)
and operate pump lever (4) until oil emerges free
from bubbles at bleeder hole (13). To ensure com-
plete bleeding of the annular chamber in ram cylin-
der (11), put rams (11), inclined towards bleeder
(13), at a highter level than pump (1). Tighten bleed
plug (13).
Caution!
All parts of the hydraulic device must be in
perfect shape. This applies in particular to
Fig. 3 Hydraulic clamping device (83230_0) the hoses, which must never be sharply bent
Design and function or pulled.
Pump (1) builds up oil pressure which reaches rams Note
(11) through hoses (8). Overpressure is avoidedby a If trouble arises, for instance with the buil-up or drop
relief valve. Gauge (7) is used for setting the oil of hydraulic pressure, proceed as follows: with
pressure required for the specific screwed joint. pump (1) in vertical position (hose connection
Hand wheel (6) is turned to let off pressure after- down), work lever (4) quickly up and down, while
wards. Safety hose couplings (10) and (12) are opening and closing shut-off wheel (6). Bleed hoses
used in combination with H.P. hoses (8) and distri- and rams.
butor (9).
Included in the set of reserve parts supplied with the
All coupling connections not utilized are perfectly engine is a pressure gauge also fited with a safety
tight where less than four rams are operated (see half-coupling (12) for connection to one of hoses (8);
page 1). this spare gauge can be used for calibrating regular
The normal working position of pump (1) is horizon- gauge (7).
tal, but the vertical position - hose connection down
- is also permissible.
Filling and bleeding
Note
Use only one of the following hydraulic oils:
BP Energol Hydraulic 50
BV E 100 Heavy-duty Oil
Esso Zerice 36
Gasolin Special AS
Mobil Hydraulic Oil
Shell AB 1 OIL
Shell Tellus 15 Oil
Viscobil Sera I Oil
Viscobil CL 40 Oil
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Drive mechanism
02.16.03
Handling the 180-mm-diameter hydraulic tool for annular nuts
Tools
- Standard tools
- Hydraulic tool 180 mm ø
- Hydraulic pump with pressure gauge
- Hoses and distributor
- Feeler gauge
Cross-references
- Job Card 02.00.01, 02.07.01, 02.08.01
Note Caution!
This tools is used both for releasing and tightening Make sure that pressurized hoses not con-
annular nuts of main bearings. nected are blanked off with a nipple.
Releasing nuts (8) Using wrench (30), screw in piston (27) until flush
with ring (24). Back through one turn. Operate pump
until the specified oil pressure is obtained (see Tigh-
tening Instructions).
Should annular nut (8) still not be loose, slowly raise
pressure through another 10 to 20 bar.
Caution!
Check that, while pumping up, piston (27)
will not go beyond marking groove (23), or
piston may be pressed beyond its stop and
press out in turn circlip (28).
Introduce tommy bar (21) through hole in counter
piston (22) and screw nut (8) up as far as it will go
and back through one turn. Let off oil pressure. Uns-
crew hydraulic tool and press in piston (27) until
flush with ring (24), provided hose is connected to
pump. Detach hoses (25) from tools.
Unscrew nut (8) with washer (9).
Fig. 1 Releasing nuts (83204_0) Repeat procedure on inner studs (7.2).
Clean seats for hydraulic tools. Screw both tools
with hoses on both outer studs (7.1) of main bea-
rings until counter piston (22) rests on washer (9).
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Drive mechanism
02.16.03
Tightening nuts (8)
Fig. 2 Tightening nuts(83231_0)

Screw hydraulic tools plus pump on inner studs
(7.2), proceeding as on page 1. Build up pressure
(see Tightening Instructions) so studs are expan-
ded.
Use tommy bar (21) to screw down nuts (1) until
squarely seated. Check this by inserting 0.1 mm
feeler gauge through recess (26) in counter piston
(22). Let off all pressure and check that nuts are
tight.
Since nuts may settle afterwards, pump up pressure
as above and, if necessary retighten nuts.
Note
Due to bearing shell protrusion, retightening nuts by
tommy bar may result in a varying number of partial
turns.
Let off pressure, unscrew hydraulic tools and push
in piston (27) until flush with ring (24), which requi-
res hose to be connected to pump.
JC 02 - Page 64 0299 6473-0125 © 0201

Drive mechanism
02.17.01
Locating bearing removal/refitment, In-line engine
Tools
- Standard tools
- Removing / refitting device (angle irons)
- Locking wire of 1 mm dia.
Cross-references
- Job Card 02.00.01, 02.03.03
Note
The two bearing segments (7) are fitted on both
sides of the crankshaft gear which is flange-moun-
ted at the engine’s driving end.
Job
Observe safety precautions (Job Card 02.00.01)
Removing the bearing
Detach covers (5) and (9).
Turn crankshaft until axial tapholes in flange (13)
are located below the segment (7) concerned.
Screw angle irons (18) to flange (13) and segment
(7) by means of two M10x15 hex. bolts (see detail
“Z”). Release hex. nut (3) and pressure screw (4) of
segment (7) and remove retainer (1) upon removal
of locking wire (16) (see detail “X”). On the far side,
remove plug-in pipe (11) and plate (17) after unlok-
king (see detail “Y”).
Turn crankshaft flange (13) c/w segment (7) to the
crankcase aperture. Detach angle irons (18) and
take out segment.
Fig. 1 Driving end (83232_0)
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Drive mechanism
02.17.01
Refitting the bearing

Secure segment (7) to flange (13) through crank-
case aperture, using two angle irons (18). Turn seg-
ment (7) by crankshaft into proper position. In doing
so, make sure that segment (7) will not be twisted or
jammed.
Attach plate (17) by bolts (14). Fit pipe (11) with new
gasket (10) and 0-seal (12) by bolts (15). Lock bolts
(14) and (15) by wire (16). On the far side, attach
retainer (1) by bolts (2) and lock by wire (16).
Tighten pressure screw (4) firmly and then back it
through a quarter turn; lock screw by nut (3).
Remove angle irons (18).
Check crankshaft end float (Job Card 02.03.03).
Refit cover (5) with new gasket (6) and cover (9)
with new gasket (8). Fig. 2 Detail X (83233_0)
Fig. 3 Detail Y (83234_0)
Fig. 4 Detail Z (83235_0)
JC 02 - Page 66 0299 6473-0125 © 0201

Drive mechanism
02.17.01
Locating bearing removal/refitment, V-type engine
Tools
- Standard tools
- Removing / refitting device (angle irons)
- Locking wire of 1 mm dia.
Cross-references
- Job Card 02.00.01, 02.03.03, 05.04.01
Note Turn crankshaft (6) until the axial tapholes in the

The two bearing segments (7) are fitted on both crankshaft flange are located below the segment
sides of the crankshaft gear. concerned. Screw angle irons (11) to crankshaft (6)
and to segment (5) by means of two M10x15 hex.
Job bolts (12) (see detail “X”). Loosen pressure screw
Observe safety precautions (Job Card 02.00.01) (4) of the segment and remove retainer (2), plate (7)
and plug-in pipe (14) on the far side. Turn cranks-
Removing the bearing
haft (6) with the segment to the crankcase aperture
Detach cover (1). Isolate governor (10) from linkage access hole, unscrew angle irons (11) and remove
(Job Card 05.04.01). Remove housing (8) from the segment (5) through the aperture.
timing chest as well as any interfering pipework.
Fig. 1 Driving end (83417_0)
© 0201 0299 6473-0125 JC 02 - Page 67

Drive mechanism
02.17.01

Secure segment (5) with angle irons (11) through
the crankcase aperture to crankshaft (6). Turn seg-
ment smoothly by the crankshaft into the correct
position.
Attach plate (7) and plug in pipe (14) with a new
gasket. Lock bolts (13) and (15) by wire. On the
other side mount retainer (2) and lock bolts (3) by
wire. Tighten pressure screw (4) firmly and then
back it through a quarter turn; lock screw by hex.
nut. Remove angle irons (11).
Check crankshaft end float (Job Card 02.03.03).
Refit cover (1), housing (8) and reconnect any
piping removed. Reconnect governor (10) to its lin-
kage (Job Card 05.04.01).
Fig. 2 Detail X (83418_0)
Fig. 3 Detail A-B (83419_0)
JC 02 - Page 68 0299 6473-0125 © 0201

Crankcase
03.01.01
Crankcase relief valve inspection/servicing
Tools
- Standard tools
Cross-references
- Job Card 02.00.01
Inspection Reassembling the valve

Inspect crankcase door gaskets and check that Reassembly is made in the reverse order.
relief valves work properly. Refit relief valve (7) with new gasket (10) to door (1)
Job and test its proper funtioning.
Open crankcase observing the safety instructions in
Job Card 02.00.01.
Unscrew bolts (2) from crankcase doors (1) and
remove relief valve (7). Press valve together from
inside and release: should plate (6) bind or spring
(9) fail to press back the plate against 0-seal (4),
dismantle valve and clean.
Servicing
Dismantling the valve
Remove screws (5).
Caution!
Plate (6) is springloaded!
Remove gasket (10) and 0-seal (4) along with its
carrier (8). Take plate (6) and spring (9) out housing
(3).
Clean all parts and replace any defective items. This
applies in particular to gasket (10) and 0-seal (4).
Fig. 1 Relief valve (83236_0)
© 0301 0299 6474-0125 JC 03 - Page 1

Crankcase
03.01.01
JC 03 - Page 2 0299 6474-0125 © 0301

Crankcase
03.02.01
Cylinder liner (in situ) servicing
Tools
- Standard tools
- No. 100 emery cloth
- Manual grinder with flexible shaft
Cross-references
- Job Card 02.09.01, 03.03.01
Servicing
At every piston inspection, examine also liner run-
ning surface and cylinder head gasket seat.
Note
Heavily scored liners, e.g. due to sharp-edged
piston rings, must be replaced. Automatic rehoning
may be possible. Please get in touch with your
DEUTZ Service in this regard.
Job
Prior to cleaning liner (1), cover up the crankcase
interior below. Heavy TDC reversing marks of top
ring (3) must be removed before installing any over-
size piston rings. To avoid damage to liner (1) in the Fig. 1 Cylinder liner (83466_0)
reversing zone and below, the following procedure
is recommendable:
Place on top of piston (2) a plate (7) of 3 - 5 mm
smaller diameter than the liner bore, the plate
having a pasted-on foam rubber lining (6). By
turning the crankshaft and with the aid of bolts (5),
bring plate (7) to such a level that remachining with
tapered grinding stone (4) will not damage the run-
ning surface of the liner. For the grinding operation,
use a manual grinder with flexible shaft.
Fig. 2 Sealing (83467_0)
© 0301 0299 6474-0125 JC 03 - Page 3

Crankcase
03.02.01
Fig. 3 Tool (83239_0)

Note
Liners are roughened whenever pistons are remo-
ved. Please get in touch with your DEUTZ Service
in this regard.
When the job is finished, clean liner thoroughly.
Caution!
After cleaning the cylinder liner, gauge the
wear,
JC 03 - Page 4 0299 6474-0125 © 0301

Crankcase
03.03.01
Cylinder liner inspection/gauging
Check TDC piston reversing mark. If it exceeds Tools

0.2 mm or so, gauge liner by stadia. Following
installation of a new liner, a check for roundness will - Stadia (fabricated locally)
be sufficient. - Inside micrometer with block gauge
Cross-references
- Job Card 03.04.01
Note Gauging levels from liner top edge:

To begin with, carefully clean liner and stadia and a = 104 mm
cover up the crankcase interior below the liner. b = 200 mm
Job c = 500 mm
Set micrometer to nominal liner bore. Suspend sta-
dia (1) in liner (2). Gauge liner axially and radially at
the stadia levels provided. To do this, hang stadia in
the respective direction.
The gauging levels are provided by 3 holes in the
stadia. Record all readings. When the specified limit
is exceeded, replace liner.
Removal see Job Card 03.04.01.
Dimensions in mm Max. Wear

Limit
Meas. point Nominal size
A 370.78
370 +0.035
B 0 370.70
C 370.30
Caution!
If 0.30 mm ovality is exceeded, remove liner
and trace cause of trouble
Fig. 1 Cylinder liner (83468_0)
© 0301 0299 6474-0125 JC 03 - Page 5

Crankcase
03.03.01
Data Sheet for cylinder liner
Date of inspection: .................
Dimensions in mm Max. permiss.

worn dimen-
Meas. point Nominal size sion
A 370.78
370 +0.035
B 0 370.70
C 370.30
Engine Ser. No.
Running hours
Running hours since

last inspection
Engine’s longit. direction
Fig. 3 Dimensions (83469_0)
JC 03 - Page 6 0299 6474-0125 © 0301

Crankcase
03.03.01
Cylinder Running A B C (1)

hours
D1 D2 D1 D2 D1 D2
A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
B3
B4
B5
B6
B7
B8
(1) Enter reason(s) for renewing:

W = Wear
F = Flaws
O = Out of round
S = Scores
© 0301 0299 6474-0125 JC 03 - Page 7

Crankcase
03.03.01
JC 03 - Page 8 0299 6474-0125 © 0301

Crankcase
03.04.01
Cylinder liner removal, without scraper ring
Tools
- Standard tools
- Hoist
- Liner removing/refitting device
Cross-references
- Job Card 01.04.01, 02.05.01, 02.09.01,
03.03.01
Note
To begin with, gauge liner
Job (In-line engine)
Drain water from jackets. Cover up crankcase
interior. be sure locating marks are provided bet-
ween liner flange (8) and crankcase (7).
Mount liner tool with bridge (3), bush (4), flat iron (5)
and puller studs (6).
When introducing puller studs (6), be sure not to
damage the liner.
Push flat iron (9) over studs (6) against liner bottom
and screw nuts (10) in place, seeing to it that free
threads of studs are equal.
Tighten nuts (2) of bridge (3) evenly until liner (8)
pulls out of crankcase (7) and hangs down slack in
ist guide. Attach hoist to lug (1) and completely pull
out liner (8) from crankcase (7). Put liner down on
wooden support.
Fig. 1 Removing device, In-line engine (83243_0)
© 0301 0299 6474-0125 JC 03 - Page 9

Crankcase
03.04.01
Job (V-type engine)

interior below liner. Make sure that there are loca-
ting marks provided between liner flange and crank-
case. Place bridge (3) on crankcase (5). Insert
puller studs (4) through bridge guide holes into liner
(6).
Caution!
Be sure the studs will not strike the liner run-
ning surface.
Push cross-piece (8) over studs (4) against liner
bottom and screw nuts (7) in place as far as they will
go. Tighten nuts (2) of bridge (3) evenly until liner (6)
pulls up out of the crankcase and hangs down slack
in its guide. Attach hoist to lug (1) and completly pull
out liner along its angled centre line. Put down liner
(6) on a timber block.
Fig. 2 Removing device, V-type engine (83420_0)
JC 03 - Page 10 0299 6474-0125 © 0301

Crankcase
03.04.01
Cylinder liner removal, with scraper ring
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 01.04.01, 02.05.01, 02.09.01,
03.03.01
Note
To begin with, gauge liner
interior. be sure locating marks are provided bet-
ween liner flange (8) and crankcase (7).
Mount liner tool with bridge (3), bush (4), flat iron (5)
and puller studs (6).
When introducing puller studs (6), be sure not to
damage the liner.
Push flat iron (9) over studs (6) against liner bottom
and screw nuts (10) in place, seeing to it that free
threads of studs are equal.
Tighten nuts (2) of bridge (3) evenly until liner (8)
pulls out of crankcase (7) and hangs down slack in
ist guide. Attach hoist to lug (1) and completely pull
out liner (8) from crankcase (7).
Remove O-seal from groove (14). Clean and
degrease groove (14).
Put liner down on wooden support.
Fig. 1 Removing device, In-line engine (83472_1)
© 0301 0299 6474-0125 JC 03 - Page 11

Crankcase
03.04.01
Job (V-type engine)

interior below liner. Make sure that there are loca-
ting marks provided between liner flange and crank-
case. Place bridge (3) on crankcase (5). Insert
puller studs (4) through bridge guide holes into liner
(6).
Caution!
Be sure the studs will not strike the liner run-
ning surface.
Push cross-piece (8) over studs (4) against liner
bottom and screw nuts (7) in place as far as they will
go. Tighten nuts (2) of bridge (3) evenly until liner (6)
pulls up out of the crankcase and hangs down slack
in its guide. Attach hoist to lug (1) and completly pull
out liner along its angled centre line.
Remove O-seal from groove (14). Clean and
degrease groove (14).
Put down liner (6) on a timber block.
Fig. 2 Removing device, V-type engine (83473_1)
Fig. 3 Removing O-seal (82937_1)
JC 03 - Page 12 0299 6474-0125 © 0301

Crankcase
03.04.02
Cylinder liner (removed) servicing
Aids
- Cleaning tools
Cross-references
- Job Card 03.02.01, 09.01.01
Servicing
Replace liner when the wear limit is reached or
reconditioning is due.
Job
Inspect liner interior, especially in the reversing
zone of the upper piston rings according to Job
Card 03.02.01.
Thoroughly clean liner (5) outside, especially the 0-
seal grooves (3). Heavy scale deposits will suggest
the use of unsuitable cooling water (see Job Card
09.01.01). The general liner condition shall govern
the decision to pull further liners or not.
Cover up crankcase interior below jackets (2) and
clean jacket walls, seat of liner flange (4) as well as
0-seal guide faces including inclined faces (7) for
easier 0-seal fitting. After cleaning carefully, check
the entire collar zone for cracks. If the sealing sur-
faces at the collar are no longer inorder, reface.
Any flaws in the crankcase in the zone of the liner
seating can be remedied by means of a DEUTZ
refacing device.
© 0301 0299 6474-0125 JC 03 - Page 13

Crankcase
03.04.02
JC 03 - Page 14 0299 6474-0125 © 0301

Crankcase
03.05.01
Cylinder liner refitment, without scraper ring
Tools Spare parts

- Standard tools - Cylinder liner
- Hoist
Aids
- Lubricant DEUTZ S2 and DEUTZ F5
- 2 blocks of square timber of 450 mm
length
Cross-references
- Liner retainer (clamping device)
- Job Card 00.01.03, 01.09.01, 02.09.01,
02.14.01, 03.03.01

Apply DEUTZ F5 compound to new 0-seals (11) and
(13) and install seals in their grooves without twi-
sting them. If gasket (14) is still in good shape, apply
DEUTZ S2 and install gasket in its seat in crankcase
(7).
Insert liner tool into liner (8) and srew nuts (10) in
place until liner is clamped down tight between flat
irons (5) and (9). Attach liner to hoist into crankcase
(7). Be careful that marked points A and B on cylin-
der liner and crankcase coincide with cylinder No. at
timing side. Remove liner tool.
Should liner (8) fail to slide onto its seat on its own,
press it home by means of the clamping device des-
cribed in Job Card 02.09.01.
Gauge liner according to Job Card 03.03.01.
Clean liner (8) thoroughly and remove blanketing
from crankcase interior.
Caution!
Run in engine, see Job Card 00.01.03.
Fig. 1 Liner refitment, In-line engine (83245_0)
© 0301 0299 6474-0125 JC 03 - Page 15

Crankcase
03.05.01
Job (V-type engine)

Apply DEUTZ F5 to new O-seal (9) and (11) and
install seals in their grooves without twisting them. If
gasket (12) is still in good shape, apply DEUTZ S2
and install gasket in its seat in crankcase (5). Place
two blocks of square timber (13) between bridge (3)
and liner flange, attach liner (6) to hoist and insert
into crankcase (5). Be careful that marked points A
and B on cylinder liner and crankcase coincide with
cylinder No. at timing side.
Caution!
Fig. 2 Liner refitment, V-type engine (83421_0)
JC 03 - Page 16 0299 6474-0125 © 0301

Crankcase
03.05.01
Cylinder liner refitment, with scraper ring
Tools Spare parts

- Standard tools - Cylinder liner
- Hoist - O-seals
Aids
- 2 blocks of square timber of 450 mm
length - Lubricant DEUTZ S2 and DEUTZ F5
- Liner retainer (clamping device)
Cross-references
- Job Card 00.01.03, 01.09.01, 02.09.01,
02.14.01, 03.03.01

Apply DEUTZ F5 compound to new 0-seals (11) and
install seals in their grooves without twisting them.
Insert liner tool into liner (8) and srew nuts (10) in
place until liner is clamped down tight between flat
irons (5) and (9). Suspend cylinder liner (8) in lifting
tackle.
Fit new O-seal to groove (14) and apply lubricant
DEUTZ F5 to it.
Insert cylinder liner (8) carefully into crankcase (7).
Be careful that marked points A and B on cylinder
liner and crankcase coincide with cylinder No. at
timing side. Remove liner tool.
Caution!
Fig. 1 Liner refitment, In-line engine (83470_1)
© 0301 0299 6474-0125 JC 03 - Page 17

Crankcase
03.05.01
Job (V-type engine)

Apply DEUTZ F5 to new O-seal (9) and (11) and
install seals in their grooves without twisting them.
Place two blocks of square timber (13) between
bridge (3) and liner flange. Suspend cylinder liner
(6) in lifting tackle.
Fit new O-seal to groove (14) and apply lubricant
DEUTZ F5 to it.
Insert cylinder liner (6) in crankcase (5).
Be careful that marked points A and B on cylinder
liner and crankcase coincide with cylinder No. at
timing side.
Caution!
Fig. 2 Liner refitment, V-type engine (83471_1)
JC 03 - Page 18 0299 6474-0125 © 0301

Crankcase
03.05.01
Fig. 3 Round sealing rings (82939_0)
Fig. 4 O-seal (82937_1)
© 0301 0299 6474-0125 JC 03 - Page 19

Crankcase
03.05.01
JC 03 - Page 20 0299 6474-0125 © 0301

Crankcase
03.07.01
Engine foundation studs inspection
Tools
- Standard tools
- Hydraulic tool (135 mm dia.) for annular
nuts
Cross-references
- Job Card 02.02.01, 02.16.01
Inspection
Make sure that engine mounting has resisted to
thermal stressing and internal strain. Check tight-
ness of all studs/nuts even where pipework renders
the access difficult.
Engine fastening using shims
Strike shims (2) with a hammer and check that this
will produce a solid metallic sound. Failing this, nuts
(1) are liable to be slack and must therefore be
retightened according to Job Card 02.16.01 and the
tightening instructions. Following this, gauge crank-
web deflection (see Job Card 02.02.01).
Note
Exercize utmost cleanliness. Keep in particular oil
and water away from foundation.
Engine fastening using plastics grouting (not
shown)
For detailed tightening instructions consult DEUTZ. Fig. 1 Engine foundation studs (83248_0)
© 0301 0299 6474-0125 JC 03 - Page 21

Crankcase
03.07.01
JC 03 - Page 22 0299 6474-0125 © 0301

Crankcase
03.09.01
Crankcase breather inspection
Inspection Tools
Make sure that breather has free passage. - Standard tools
Job
Open drain valve (4) and let out condensate from
cover plate (2). If no condensate comes out, check
that valve (4) is not blocked.
Remove flanged jont (1). Inspect breather chamber
between cover plates (2) and (3) for deposits. If
necessary, take plates (2) and (3) down and clean.
Refit joint (1).
Fig. 2 Flange (83250_0)
Fig. 1 Crankcase breather(83249_0)
© 0301 0299 6474-0125 JC 03 - Page 23

Crankcase
03.09.01
JC 03 - Page 24 0299 6474-0125 © 0301

Engine control
04.01.01
Camshaft bearing gauging/reconditioning
Gauging Tools
Measure bearing running clearance. - Standard tools
- Feeler gauge
Cross-references
- Job Card 02.00.01
Note
You do not need to remove the camshaft in order to
replace the camshaft bearings. Always replace a
complete bearing at any one time.
Job
Following removal of cover (8), check by feeler
gauge that shaft/bearing clearance is as specified
hereunder
New condition Wear limit

(mm) (mm)
Radial 0.1...0.171 0.25

clearance Fig. 1 Camshaft bearing (83251_0)
Once the wear limit is reached, replace the com-
plete bearing. Install new shells in bearing housing (5) and cap (7).
Fit cap (7) along with dowel pins (6). Screw bolts (4)
Reconditioning together with washers (3) into the camshaft casing.
Removing the bearing Tighten bearing housing (5) against crankcase by
means of bolt (9). Tighten bolts (4) together with
Unscrew waisted bolts (4). Take down bearing hou-
washers (3) as specified. Attach cover (8).
sing cap (7), paying attention to both dowel pins (6).
Remove lower shell (2) and radially turn out upper
shell (1).
© 0301 0299 6475-0125 JC 04 - Page 1

Engine control
04.01.01
JC 04 - Page 2 0299 6475-0125 © 0301

Engine control
04.01.02
Camshaft locator inspection/reconditioning
Inspection Tools
Measure end float (axial clearance) of camshaft on - Standard tools
uni-directional engines.
- Feeler gauge
Job
Measure end float by placing dial gauge against
shaft end or a cam and moving shaft in both direc-
tions.

(mm) (mm)
Axial clearance 0.15...0.25 0.3
Once the wear limit is reached, recondition locator

assembly.
Reconditioning
Removing thrust ring (12)
Unscrew bolts (9) and take down cover (10). Uns-
crew waisted bolt (8). Take stop plate (11) and thrust
ring (12) out of housing (3).
Clean all components. If necessary, smoothen run-
ning surface of stubshaft (4), thrust ring (12) and
stop plate (11) or replace.
Removing/refitting stubshaft (4) Fig. 1 Camshaft locator (83252_0)
Unscrew bolts (2). Withdraw housing (3) from crank-
case (18). Unscrew waisted bolts (6) from camshaft
(17) and waisted bolts (12) from half-rings (16).
Take down stubshaft (4).
© 0301 0299 6475-0125 JC 04 - Page 3

Engine control
04.01.02
Note
Waisted bolt (6) is provided
on in-line LH engine
on V-type engine LH side
Waisted bolt (14) is provided
on in-line RH engine
on V-type engine RH side.
Attach new stubshaft (4). Screw waisted bolts (6)

and (14) respectively in place and tighten through
157 Nm troque. Mount housing (3) with intact gasket
(1) and dowel pin (15) to crankcase (18).
Refitting thrust ring (12)
Position ring (12) with stop plate (11) and dowel pin
(13). Scres waisted bolt (8) in place and tighten
through 236 Nm. Replace 0-seals (7) if in bad
shape. Introduce cover (10) into housing (3) and
secure by bolts (9). Check camshaft end float.
JC 04 - Page 4 0299 6475-0125 © 0301

Engine control
04.02.01
Roller tappet reconditioning
Tools
- Standard tools
- Feeler gauge
Aids
- Compressed air
Cross-references
- Job Card 01.01.01, 02.00.01
Reconditioning
Recondition for instance when tappet roller is defec-
tive.
Job
Removing the tappet
Turn camshaft until roller (17) rests on the base
circle of cam (18). Remove rocker chamber cover.
Loosen nuts (3) from both rocker arms (1) and turn
up pressure screws (2). Unscrew bolts (5) and
remove lokking plate (6). Tilt pushrod (4) sideways
and withdraw.
Fold up both rocker arms (1) and withdraw cover
tubes (8) from chamber (7).
Unscrew bolts (9). Remove lockwashers (10) and
washers (11). Take guide bush (12) with tappet (15)
out of camshaft housing (16).
Caution! Fig. 1 Valve mechanism (83253_0)
Take care that tappet (15) will not fall out of

guide bush (12).
Clean all components. Apply an air blast through oil
passages and check that the latter are free.
Inspect all parts for wear, especially bush (12), tap-
pet (15), roller (17), roller pivot pin (19) and socket
(14).
Replace any defective item. When renewing roller
(17), roller pivot pin (19) must also be renewed.
© 0301 0299 6475-0125 JC 04 - Page 5

Engine control
04.02.01
Fig. 2 Tappet (83254_0)

Refitting the tappet
When refitting, centre the roller (17) by means of
guide mandrel and, after installation, check for late-
ral clearance (min. 0.15 mm).
Check roller (17) for free movement on pivot pin
(19), and in tappet (15).
Apply oil to tappet (15) and its bush (12). Assemble
both and introduce with new 0-seal (13) into cams-
haft carrier case (16).
Screw bolts (9) together with washers (11) and lock-
washers (10) in place. Check that tappet (15) moves
easily in its guide bush (12). Introduce cover tube
(8) with new 0-seals into rocker chamber (7) and
install into bush (12). Install pushrod (4).
Install locking plate (6). Set valve clearance (Job
Card 01.01.01). Mount rocker chamber cover.
JC 04 - Page 6 0299 6475-0125 © 0301

Engine control
04.04.01
Idler gear removal/refitment, In-line engine
Tools
- Standard tools
- Hoist
- Locking wire
Cross-references
- Job Card 04.05.01, 04.08.01, 04.15.02
Note
Removal of idler gear II is possible only following
removal of camshaft gear III and auxiliary drive with
gear IV.
Job
Remove camshaft gear III (Job Card 04.05.01) and
auxiliary drive with gear IV (Job Card 04.15.02).
Disconnect from timing chest any piping interfering
with idler gear removal and detach associated
inspection and access hole covers from timing
chest from and side.
Removing the idler gear
Disconnect oil line (3).
Unscrew hex. bolts (4) and take down washers (5).
Remove both bearing covers (1). Raise idler gear II
by hoist out of carrier (12) up to bore (8) of removed
flanged bearing (7). Take down rings (6) and with-
draw fulcrum pin (9) through bore of flanged bearing
(8).
Fully remove idler II gear in upward direction.
Fig. 1 Idler gear (83255_0)
Remove screws (11) to part the two gears. When
reassembling the idler gear, tighten screws (11)
through 157 Nm.
© 0301 0299 6475-0125 JC 04 - Page 7

Engine control
04.04.01
Refitting the idler gear

Lower idler gear II by boist down to level of flanged
bearing bore (8). Introduce fulcrum pin (9) into gear.
Fit rings (6). Lower gear farther down to the bea-
rings of gear carrier (12). Lock fulcrum (9) by dowel
pin (10) in carrier. Mount both bearing caps (1),
paying attention to dowel pins (2). Screw in bolts (4)
with washers (5) and tighten as per Tightening
Instructions. Connect oil line (3) with new gasket.
Install camshaft gear III (Job Card 04.05.01) and
mount auxiliary drive with gear IV (Job Card
04.15.02).
Check gear backlash (Job Card 04.08.01).
Attach inspection and access hole cover plates.
Reconnect all piping removed.
Fig. 2 Section A-B (83256_0)
JC 04 - Page 8 0299 6475-0125 © 0301

Engine control
04.04.01
Idler gear removal/refitment, V-type engine
Tools
- Standard tools
- Hoist
- Locking wire
Cross-references
- Job Card 04.05.01, 04.05.02, 04.08.01,
04.15.02
Note
Removal of idler gears is possible only following
removal of the associated camshaft gear with adap-
ter. Before removing idler gear on the auxiliary gear
train side, remove idlers IV and V.
Job
Remove camshaft gears III (Job Card 04.05.01).
Remove auxiliary drive (1) (Job Card 04.15.02).
Remove any interfering piping from timing chest.
Detach associated inspection and access hole
covers from timing chest front and sides.
Removing idler gears IV and V, Fig. 2
Disconnect oil pipe (6).
Unscrew waisted bolts (3) and take down washers
(2). Withdraw gears IV and V from flanged pivot pin
(7).
Removing idler gear II, Fig. 3
Disconnect oil pipe (10). Unscrew waisted bolts (11)
and take down washers (12). Remove both bearing
caps (14). raise gear II by hoist out of gear carrier
(9) up to hole (10) for flanged bearing. Remove
rings (16) and withdraw fulcrum (17) through the
flanged-bearing hole. Take gear II out of the timing
chest. Remove screws (18) and part cluster gear. Fig. 1 Idler gears (83422_0)
For joining cluster gear II, tighten screws (18)
through 157 Nm.
© 0301 0299 6475-0125 JC 04 - Page 9

Engine control
04.04.01
Fig. 2 Section E-F (83423_0)

Refitting idler gear II
Through upper aperture in timing chest, raise clu-
ster gear II by hoist up to hole of flanged bearing
Fig. 3 Idler gears (83424_0)
(19).
Push fulcrum (17) into gear and fit rings (16). Lower
gear II into support of gear carrier (9). Lock fulcrum
(17) by parallel pin (15) in gear carrier (9). Install
both bearing caps (14), paying attention to dowel
pins (13). Screw waisted bolts (11) with washers
(12) in place and tighten as per Tightening Instruc-
tions. Connect oil line (10) with new gasket.
Refitting idler gears IV and V
Slip gears IV and V over flanged pivot pins (7). Fit
washers (2), paying attention to dowel pins (4).
Screw bolts (3) in place and tighten through 98 Nm.
Fit camshaft gears III (Job Card 04.05.01) and auxi-
liary drive (1) (Job Card 04.15.02).
Check backlashes (Job Card 04.08.01).
Mount inspection and access hole covers on timing
chest. Connect pipework.
JC 04 - Page 10 0299 6475-0125 © 0301

Engine control
04.05.01
Camshaft removal
Tools
- Standard tools
- Hoist
- Depth gauge
- Flat steel wedge
- Hard timber chock
Cross-references
- Job Card 02.00.01,04.01.01, 04.01.02,
04.02.01, 04.07.03, 05.04.01,
05.04.02, 06.02.01, 07.04.01, 07.06.01
Note
To ensure correct refitment of camshaft, measure
prior to removal the distance “Y2”, relative to the
top edge of the shim of the individual cylinders
(camshaft in compression TDC). For distance “Y2”
Preparatory work
Mark all parts to be removed. Detach operators’s
platform. Disconnect all interfering pipework (fuel,
lube oil, backleakage, plunger sealing oil, nozzle
coolant, compressed air) and remove all interfering
sections of the charge air pipe (Job Card 06.02.01).
Detach injection pumps (Job Card 07.04.01).
For measuring camshaft position, turn engine until
No. 1 piston is in compression TDC. Use a depth
gauge to determine dimension “Y2” from the top
edge of shim (1) to the top edge of the thrust plate
(4) in pump drive (6) of cylinder 1 and record rea- Fig. 1 Injection pump (25535_0)
ding on a test sheet. Repeat this with all other cylin-
ders also.
On direct-reversible models perform measurement
inthe opposite direction as well.
Caution!
Never change direction of camshaft rotation
while setting compression TDC.
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Engine control
04.05.01
Removing components at engine driving end Mark all camshaft bearings relative to each other
(see figure overleaf) and to the carrier case. Remove bearing cap (25)
Remove starting pilot air distributor (15), paying (Job Card 04.01.01) and unscrew bolt (23) from
attention to dowel pins. Detach upper and lateral bearing housing (24).
access hole covers from timing chest and discon-
nect oil supply line (12). Unscrew bolts (16), paying
attention to dowel pins (13), and take down flanged
bearing (14). Unscrew waisted bolts (11) and take
down stubshaft (17), paying attention to dowel pins
(18). Unscrew waisted bolts (10).
Remove clamping ring (19) and camshaft gear III
through the upper aperture. Unscrew bolts (8).
Remove spacer (21) and adapter (20), paying atten-
tion to dowl pins.
Remove crankcase doors (35) to remove pushrods,
cover tubes and tappets (Job Card 04.02.01). Take
plunger lock (5) out of camshaft carrier case and
withdraw pump drive (6) in upward direction.
Removing components at engine free end
Uni-directional engine:Remove Thrust ring and hou- Fig. 3 Camshaft bearing (83258_0)
sing (Job Card 04.01.02).
Direct-reversible engines: Remove reversing oil
reservoir and reversing mechanism (Job Card
04.07.03).
Detach cover (32) from camshaft carrier cases (22)
and remove governing linkage (Job Card 05.04.02).
Remove arched pieces (27). Detach governor from
auxiliary drive (Job Card 05.04.01).
Fig. 2 Starting pilot air distributor (83257_0)

Support camshaft (33) by wooden chocks through
the lateral access holes. Remove camshaft in axial
direction.
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Engine control
04.05.01
Removing single camshaft pieces with camshaft Remove the camshaft case (22) fitted above the
in situ camshaft piece you want to remove. For how to
For reconditioning etc., it is possible to remove sin- remove a camshaft piece, see Job Card 04.05.01.
gle pieces without removing the whole shaft. Before lifting out the camshaft pieces, shift the
camshaft pieces remaining in the engine in an axial
Carry out the preparations as described on Page 1 direction.
of this Job Card, as far as removal of the fuel injec-
tion pumps. Take off the cover of the flywheel hou- Note
sing at the drive end. Endwise movement on uni-directional engines may
require removal of thrust ring (Job Card 04.01.02).
Fig. 4 Housing (83259_0)
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04.05.01
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Engine control
04.05.02
Camshaft reconditioning
Tools
- Standard tools
Cross-references
- Job Card 04.05.01, 04.06.01
Reconditioning Job
If reconditioning is required (broken cams or defec- Remove complete camshaft (Job Card 04.05.01).
tive cam running surfaces), it is also possible to Support shaft at several bearing points and retain
replace single camshaft pieces on the removed radialy following removal of any of the pieces (2).
camshaft.
Fig. 1 Camshaft (83260_0)
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Engine control
04.05.02
Remove waisted screws (1) on both sides of piece

(2) and remove piece. Install new piece and loosely
fit screws (1).
Install shaft (Job Card 04.06.01) up to the gauging
stage. Check “Y2” on all cylinders. Should the rea-
ding for the new piece depart from the rest of rea-
dings, turn shaft piece as required.
When piece (2) is in the correct position, tighten
screws (1) through 157 Nm.

Drill flanged connections of replaced piece (2) radi-
ally at point (3) and fit dowel pins. If required, bolt
piece (2) to end piece (6), paying attention to axial
dowel pin (5).
For camshaft refitment see Job Card 04.06.01.
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Engine control
04.06.01
Camshaft refitment
Tools Aids
- Standard tools - Surface-sealing Hylomar SQ 32/H
- Hoist
Cross-references
- Feeler gauge
- Job Card 01.01.01, 04.01.01, 04.06.02,
- Depth gauge 05.04.01, 06.02.01, 04.01.02,
04.07.02, 05.04.02, 07.04.01,
04.02.01, 04.07.03, 05.04.11, 07.06.01
Refitting the complete camshaft

Clean all components. Remove old sealing com-
pound from carrier cases (22) and (34).
Install shaft (33) by hoist in its trough without dama-
ging the bearings. Place bearing housing (24) on
camshaft. Note correct marking. Fit 0-seal (36).
Refitting the carrier cases
Remove grease from sealing surfaces of camshaft
casings (22), end casings (34) and upper bearing
covers (24) and coat both sides with Hylomar SQ
32/H surfaces-sealing compound (Fig. 2). Mount
end cases (34) to crankcase, so that they are flush
with crankcase. Screw in bolts (26) and tighten
through 240 Nm. Raise camshaft (33) by hoist and
fit end bearing cap (25) (Job Card 04.01.01).
Remove hoist. Position cases (22) on trough so
0.7 - 0.8 mm clearance is left between all cases.
Tighten bolts (28) through 236 Nm.
Fit sealing bushes (29) with new 0-seals (30) and
secure by dowel sleeves (31). Screw bolts (23) into
bearing housings (24). Assemble bearings (Job
Card 04.01.01). Attach governing linkage (Job Card
05.04.02). Attach covers (32) with new gasket. Fit
arched pieces (27) with new gaskets. Mount
governor (Job Card 05.04.01/ 05.04.11).
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04.06.01
Fig. 3 Housing (83264_0)

Fig. 2 Coat sealing surfaces with Hylomar
Refitting components at the engine free end
Direct-reversible engines: Fit reversing oil reservoir
and reversing gear (Job Card 04.07.02).
Uni-directional engines: Fit housing and thrust ring
(Job Card 04.01.02).
Install pump drive (6) into carrier cases and fit injec-
tion pump plunger lock (5).
Refitting components at the engine driving end
Fit spacer (21) and adapter (20) by waisted bolts (8)
and tighten through 157 Nm, paying attention to
dowel pins. Turn engine until No. 1 piston is in com-
pression TDC. Then, using a depth gauge, measure
for cylinder 1 the dimension “Y2” between shim (1)
and thrust plate (4). If necessary, turn camshaft to
obtain the measure obtained in the shaft removal
phase. Fit camshaft gear III with clamping ring (19).
Screw in bolts (10) and tighten through 157 Nm.
Check dimension “Y2” on all cylinders. (See Job
Card 07.06.01).
On direct-reversible engines check “Y2” of No. 1
cylinder in the opposite direction as well.
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Engine control
04.06.01
Mount shaft end (17) with wasted bolts (11). Tighten

bolts through 69 Nm and pay attention to dowel pins
(18).
Install flanged bearing (14), paying attention to
dowel pins (13), and secure by bolts (16). Connect
oil line (12) and mount starting pilot air distributor
(15).
Check camshaft timing (Job Card 04.06.02). Install
tappets, cover tubes and pushrods (Job Card
04.02.01).
Attach injection pumps (Job Card 07.04.01). Recon-
nect all pipework previosly removed, and reassem-
ble charge air pipe (Job Card 06.02.01). Set inlet/
exhaust valve clearance (Job Card 01.01.01) and
check shaft end float (Job Card 04.01.01/04.07.02).
Refit crankcase doors and timing chest covers.

Refitting single camshaft pieces
Install new pice B in the correct angular position and
according to the bolt hole pitch. Screw in waisted
screws D and preload.
Locate camshaft endwise. On uni-directional engi-
nes install thrust ring (Job Card 04.01.02). Refit car-
rier cases (22) as described in “Refitting the carrier
cases”.
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Engine control
04.06.01
Move piece A piston up to compression TDC and

check dimension YA. Adjust piston relative to piece
B to dimension prevailing prior to removal. Adjust
piece C relative to any cylinder unit to dimension
prevailing prior to removal. Loosely screw in waisted
screws D of pieces A and B.
Adjust setting YC = YA = YB. Preload screws D of B
and C.
Verify Setting YA,B,C and finally tighten all screws D
through 157 Nm.
For refitment of all removed components and for
final checks see pages 1 and 2 of this Job Card.
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04.06.02
Camshaft setting checking
Tools
- Standard tools
- Dial gauge and fitting device
- Fixed pointer
Cross-references
- Job Card 01.01.01, 07.04.01
Checking
Check position of camshaft relative to crankshaft in
particular following installation of a complete cams-
haft or a camshaft piece, following work on the
timing gear train as well as for checking the timing
gear mesh.
Note
The camshaft position is determined here through
the injection timing. Correct shaft setting and valve
clearance will also involve correct inlet/exhaust
valve timing. If possible, perform a check of the
camshaft position before pushrods are fitted.
Camshaft setting (In-line engine and V-type engi-
ne, LH engine side (A-bank))
Job
Secure pointer (1) to cover (5) of the timing chest at
the engine’s driving end by two bolts, paying atten-
tion to the dowel pins. Determine circumferential
length “Z” through either of the formulae below,
depending on wether the flywheel (6) periphery “U”
or diameter “D” is known. Include in the respective
formula from Acceptance Certificate a start of injec-
tion angle α° +- 0.2°. Starting form the TDC mark for
the No. 1 cylinder stamped into the flywheel, provide
mark “Z” by felt pen after turning the engine in the
respective direction.
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Engine control
04.06.02
Fig. 1 Camshaft setting (83476_0)
A Ahead
CL rotation
A1 Start of injection
CL rotation
B Ahead
CCL rotation
B1 Start of injection
CCL rotation
R In-line engine
V V-type engine
OT TDC
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Engine control
04.06.02
Remove injection pump of No. 1 cylinder (Job Card The same check can be carried out with the rest of
07.04.01). Turn camshaft in ahead direction until cylinders in the correct firing order (see Technical
No. 1 tappet roller (4) rests on the injection cam Data).
base circle short of mounting the cam. Place dial
gauge (2) with fitting device on No. 1 compensating
plate (7) and set gauge to zero.
Caution!
Where the engine is of the direct-reversible
type, check that the camshaft is in Ahead
position.
Turn camshaft (and hence crankshaft) in the ahead
direction until the dial gauge reading is 6 + 0.1 mm
as related to the injection cam base circle and check
that fixed pointer (1) on flywheel (6) agrees with the
felt pen mark. Failing this, adjust by the flanged con-
nection between camshaft drive gear and camshaft
(Job Card 04.06.01, engine free end).
Fig. 2 Injection pump (25536_0)
α X
Basic setting of Actual
camshaft w. 6 mm Depth measure geometrical COD
Rated speed upmost position with inserting shims Idle stroke
rpm +-0.2 (°Cs) +- 0.1 (mm) +- 0.1(mm) +- 0.5 (°Cs)
631 - 650 24.5 137.0 6.0 24.5
601 - 630 24.5 137.0 6.0 24.5

571 - 600 25.0 137.0 6.0 25.0
541 - 570 25.5 137.0 6.0 25.5
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Engine control
04.06.02
Camshaft setting (only V-type engine, RH engine

side (B-bank))
Beginning from start of injection ahead of No. A1
cylinder, turn crankshaft in ahead direction farther
through the degrees crank angle tabulated below
and mark flywheel by felt pen at pointer (1).
No. of cylinders Ahead direction °crank angle Cylinder No.
12 CL rotation 48 B6
12 CCL rotation 72 B5
16 CL rotation 48 B1
16 CCL rotation 42 B4
Fig. 3 Firing distance and order (83442_0)

R CL rotation
L CCL rotation
Now turn RH-side (B-bank) camshaft until tappet
roller (4) of the respective cylinder rests on the injec-
tion cam base circle short of mounting the cam.
Put gauge (2) on injection pump plunger control
gear (3) of this cylinder and take reading as descri-
bed for the A-camshaft.
Following this, mount injection pumps (Job Card
07.04.01).
Check valve clearance (Job Card 01.01.01).
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Engine control
04.07.01
Reversing oil reservoir inspection
Inspection Tools
Check oil level with engine stationary and top up as - Standard tools
required.
Cross-references
- Job Card 05.00.01
Note
Reversing manoeuvres with an insufficient oil quan-
tity are liable to damage the camshaft.
Job
Place camshaft in ahead position. Unscrew plug (1)
with dipstick from reservoir (2). Check that in the
“Ahead” reservoir the oil level reaches the minimum
mark and in the “Astern” reservoir the maximum
mark on the dipstick. Top up at (1) or drain at (3), as
the case may be.
Note
Should the oil level depart from the specified level
as a function of the camshaft position, inspect V-
seals in the reversing assembly. For reconditioning
Fig. 1 Oil reservoir (83267_0)
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04.07.01
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Engine control
04.07.02
Camshaft reversing assembly checking
Checking Tools
Check reversing assembly setting and end float, - Standard tools
especially following any work on the shaft.
- Feeler gauge
- Check pin
Aids
Cross-references
- Job Card 04.07.03
Checking the setting

Remove hood (5) and make sure that check pin (4)
can be fully introduced into check hole (3) in both
camshaft end positions.
If an adjustment is required, proceed as follows:
Unscrew slotted plug (1) from housing (2). Unlock
nut (6) and remove by socket-head wrench. Adjust
needle roller (8) by screwdriver until check pin (4)
can be introduced in hole (3) down to ist stop. Tigh-
ten nut (6) and lock by plate (7). Apply DW 51 com-
pound to thread of plug (1) and screw plug into
housing (2). Pull out check pin (4).
Checking the end float
Push camshaft to ist limit position at the engine’s
free end. Measure clearance “X” by feeler gauge.

(mm) (mm)
Axial clearance 0.15 -0.25 0.3
Once the wear limit is reached, replace both stop

plates (9) (Job Card 04.07.03). Refit hood (5).
Fig. 1 Reversing assembly (83268_0)
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04.07.02
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04.07.03
Camshaft reversing assembly reconditioning
Tools
- Standard tools
- Locking wire
Aids
Cross-references
- Job Card 04.01.02, 04.07.01, 04.07.02,
05.00.01
Reconditioning
Recondition assembly especially where checks of
oil level or end float (Job Card 04.07.01 / 04.07.02)
have proved unsatisfactory.
Removing the assembly
Slacken piping (3), drain oil from reservoirs (2) and
remove piping (3). Disconnect reversing air piping
(1) and detach reservoir (2).
Disconnect lube oil piping (17) and control air piping
(15). Detach cover (7). Unscrew waisted bolts (8) or
(32) respectively (Job Card 04.01.02, page 2) and
remove with washers (33). Unlock bolts (6) and uns-
crew. When removing assembly (4) from crankcase,
pay attention to both dowel pins (34).
© 0301 0299 6475-0125 JC 04 - Page 29

Engine control
04.07.03
Fig. 2 Reversing assembly ( 83272_0 )

Dismantling the assembly Reassembling the assembly
Remove hood (19). Unscrew bolt (18) and take Apply oil to V-seals and cylinder (31), and DEUTZ
down plate (10) and stop ring (21), paying attention DW 50 compound to new gasket (23). Stick gasket
to dowel pins. Withdraw shaft (11) from shaft (29) at to housing (12) over recess. Carefully slip cylinder
flange (9). Unscrew bolts (13) and pull off cylinder (31) over piston (26) and recess of housing (12) and
(31) from piston (26). sure by bolts (13). Insert shaft (11) c/w stop ring (10)
Inspect all components for wear or demage, especi- into shaft (29). Fit stop ring (21) and plate (20),
ally V-seals (22) and (25). Make sure by air blast paying attention to dowel pins. Screw in waisted bolt
that lube oil and control air passages are free. (18) and tighten to specification. Move flange (9)
Renew all gasket. axially and radially to check that piston (26) and
shaft (11) are free.
For replacement of V-seals, remove circlips (30).
Inspect stop rings: if scoring and/or excessive clea-
rance “X” is found, replace rings (Job Card
04.07.02).
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Engine control
04.07.03
Refitting the assembly

Position cylinder (31) with new gasket (35) and both
dowel pins (34) on the crankcase. Screw in bolts (6)
and lock with by wire. Assemble coupling. Screw in
waisted bolts (8) / (32) with washers (33) and tighten
through 157 Nm. Mount cover (7) with new gasket
(5).
Mount oil reservoir (2), and connect reversing oil
piping (3) plus air piping (1). Fill reservoir (2) with
fresh oil (job 04.07.01). Check camshaft setting and
end float (clearance “X”) (Job Card 04.07.02).
Screw hood (19) with new gasket (16) in place.
Connect lube oil piping (17) and control air piping
(15).
Perform several trial reversing manoeuvres and
check oil level in reservoirs (2) (Job Card 04.07.01).
© 0301 0299 6475-0125 JC 04 - Page 31

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04.07.03
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Engine control
04.08.01
Timing gear train inspection/gauging
Tools
- Standard tools
- Dial gauge with magnetic holder
Cross-references
- Job Card 05.00.01
Inspection/gauging Note
Inspect and gauge backlash of timing gears at the For moving camshaft gear III, release pressure
engine’s driving and free ends. screws for valve clearance adjustment.
Note If the gear mesh pattern is unsatisfactory or if the
The gear bearings are connected to the engine’s wear limit has been reached, replace the respective
main lube oil circuit, whilst the teeth are lubricated gears. Consult DEUTZ.
by oil jet. Normally, the gears need no servicing and In-line engine
have a long lifespan. Foreign particles, however,
may lead to premature wear and tear. Note
Job The gear mesh in the adjacent diagrams refers to
No. 1 piston in TDC and inlet and exhaust valves
Observe safety precautions (Job Card 05.00.01). being closed.
Inspecting the gears Backlash of driving end gears
Remove side covers from timing chest and turn
engine. Inspect gears, especially tooth flanks, for New condition
defects. Be sure all bolts are locked. Operate pri-
ming pump and check that oil jets onto idler gears II I / II 0.25 - 0.45 mm
are satesfactory.
II / III 0.05 - 0.20 mm
Gauging the backlash
Measure backlash by dial gauge. To do this, lock II / IV 0.10 - 0.25 mm
one gear by wooden chock and move meating gear
in both directions. I Gear on crankshaft
Read difference from gauge and compare with spe-
cified values overleaf. II Idler Gea
III Gear on camshaft
IV Auxiliary drive gear (governor and tacho-

generator)
Note
Definitions for LH and RH engines see Technical
Data
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Engine control
04.08.01
Backlash of free end gears
New condition
V / VI 0.20 - 0.30 mm
V / VII 0.20 - 0.30 mm
V / VIII 0.30 - 0.50 mm
V Gear on intermediate piece
VI Gear of lube oil pump
VII Gear of lube oil pump
VIII Gear of coolant pump

Fig. 2 RH engine (83274_0)
Fig. 3 Gear train (83275_0)
Fig. 1 LH engine (83273_0)
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Engine control
04.08.01
V-type engine
Note
Before removing gears, mark them relative to each
other.
Backlash of driving end gears
New condition
I / II 0.25 - 0.45 mm
II / III 0.05 - 0.20 mm
II / IV 0.10 - 0.25 mm
IV / V 0.10 - 0.25 mm
V / VI 0.15 - 0.25 mm
I Gear on crankshaft
Fig. 4 Gear train, V-type engine (83426_0)
II Idler gears
III Gears on camshaft
IV Idler gear
V Idler gear
VI Auxiliary drive gear (governor and tacho-

generator)
Backlash of free end gears
New condition Fig. 5 Gear train, V-type engine (83427_1)
X / XI 0.20 - 0.30 mm
X / XII 0.20 - 0.30 mm
X / XIII 0.30 - 0.50 mm
X Gear on crankshaft
XI Gear of lube oil pump
XII Gear of lube oil pump
XIII Gear of coolant pump
© 0301 0299 6475-0125 JC 04 - Page 35

Engine control
04.08.01
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Engine control
04.09.01
Flywheel removal/refitment (Intermediate shaft with support)
Tools
- Standard tools
- Hoist
- Brass arbor
Cross-references
- Job Card 05.00.01
Note Removing the flywheel

Refitting marks for crankshaft (14) and flywheel (6) Observe safety precautions (Job Card 05.00.01).
are an “0” at points “X”. Flywheel studs (11) and Mark position of drive flange (2) to adapter flange
associated holes in flywheel (6) are marked at (4) and of the latter to flywheel (6). Provide mating
points “Y” with a serial number. Stamped in at point marks (figures) on studs (3) and flange (4) and
“Z” of each stud (11) are the three last digits of the remove hex. bolts (16) together with ring (17). With-
engine serial No. draw drive shaft (1) together with adapter flange (4).
For removing a defective ring gear (8), unscrew hex.
bolts (7). Attach flywheel (6) with lug (18) to hoist.
Remove timing chest cover. Pull out split pins (13)
and unscrew castle nuts (12).
Drive out studs (11) by brass arbor toward flywheel
(6) and take flywheel from crankshaft (14). If drive
shaft (1) has to be separated from the adapter
flange (4), note markings when re-assembling.
Tighten studs (3) to specification and secure by split
pins (10).
Tightening instructions for studs (3):
Preload with 236 Nm and tighten in two angular sta-
ges: 1st stage 30° and 2nd stage 15°.
Fig. 1 Intermediate shaft with support (83276_0)
© 0301 0299 6475-0125 JC 04 - Page 37

Engine control
04.09.01
Refitting the flywheel

Carefully clean all joint faces of components. When
positioning flywheel (6) and fitting studs (11), note
markings.
Refitment is in the reverse order.
Renew split pins, locking plates and lockwashers.
For tightening studs (11), see Section 3.5, item 7 for
stud length 363 mm and item 8 for stud length
423 mm. Lock castle nuts by split pin (13).
Mount drive shaft (generator) (1) with the adapter
flange (4), noting the markings of the adapter flange
(4) and flywheel (6), as well as the parallel pins. Fit
hex. bolts (16) together with ring. Tightening instruc-
tions for hex. bolts (16): see Technical Data.
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Engine control
04.09.01
Flywheel removal/refitment (Overhung coupling)
Tools
- Standard tools
- Hoist
- Brass arbor
Cross-references
- Job Card 05.00.01
Note
Refitting marks for crankshaft (12) and flywheel (8)
are on “0” at points “X”. Flywheel studs (9) and
associated holes in flywheel (8) are marked at
points “Y” with a serial number. Stamped in at point
“Z” of each stud (9) are the three last digits of the
engine serial No.
Removing the flywheel
Mark position of drive shaft (1) to adapter flange (3)
and of the latter to flywheel (8). Provide mating
marks (figures) on studs (2) and flange (3) and
remove studs (2) plus drive shaft. Unscrew bolts (4)
and remove flange (3). For removing a defective
ring gear (6) unscrew bolts (5).
Mark flywheel (8) to crankshaft (12). Provide mating
Nos. on studs (9) and flywheel (8).
Attach flywheel (8) with lug (7) to hoist. Remove
timing chest cover. Pull out split pins (11) and uns-
crew castle nuts (10). Drive out studs (9) by brass
arbor toward flywheel (8) and take flywheel from
crankshaft (12).
Fig. 1 Overhung coupling, In-line engine (83277_0)
© 0301 0299 6475-0125 JC 04 - Page 39

Engine control
04.09.01

markings. Refitment is in the reverse order. Renew
split pins, lokking plates and lockwashers. For tigh-
tening studs (9), see Technical Data. Lock castle
nuts (10) by split pins (11). Attach adapter flange (3)
by bolts (4). Lock bolts (4). Install drive shaft (1).
Note marks of drive shaft (1) to flange (3) and studs
(2). Tighten studs (2) to the local specification and
secure by split pins.
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Engine control
04.09.01
Flywheel removal/refitment (Single-bearing generator)
Tools
- Standard tools
- Hoist
- Brass arbor
Cross-references
- Job Card 05.00.01
Note Removing the flywheel

Refitting marks for crankshaft (14) and flywheel (6) Observe safety precautions (Job Card 05.00.01).
are an “0” at points “X”. Flywheel studs (11) and Mark position of drive flange (2) to adapter flange
associated holes in flywheel (6) are marked at (4) and of the latter to flywheel (6). Provide mating
points “Y” with a serial number. Stamped in at point marks (figures) on studs (3) and flange (4) and
“Z” of each stud (11) are the three last digits of the remove hex. bolts (16) together with ring (17). With-
engine serial No. draw drive shaft (generator) (1) together with adap-
ter flange (4).
For removing a defective ring gear (8), unscrew hex.
bolts (7).
Attach flywheel (6) with lug (18) to hoist. Remove
timing chest cover. Pull out split pins (13) and uns-
crew castle nuts (12).
Drive out studs (11) by brass arbor toward flywheel
(6) and take flywhee form crankshaft (14). If drive
shaft (1) has to be separated from adapter flange
(4), note markings when re-assembling.
Tighten studs (3) to local specification and secure
by split pins (10).
Fig. 1 Generator (83278_0)
© 0301 0299 6475-0125 JC 04 - Page 41

Engine control
04.09.01

markings.
Refitment is in the reverse order. Renew split pins,
locking plates and lockwashers. For tightening studs
(11), see Section 3.5, item 7 for stud length 363 mm
and item 8 for stud length 423 mm. Lock castle nuts
(12) by split pin (13).
Mount drive shaft (generator) (1) with adaper flange
(4), noting the markings of adapter flange (4) and
flywheel (6), as well as the parallel pins. Fit hex.
bolts (16) together with ring.
Tightening instructions for hex. bolts (16): see Tech-
nical Data.
JC 04 - Page 42 0299 6475-0125 © 0301

Engine control
04.09.02
Flyring (Turning wheel) removal/refitment
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 05.00.01
Job
Comply with safety instructions on Job Card
05.00.01.
Note
For installation marking, crankshaft (14) and flyring
(6) are designated with a “0” at points X.
Removal
Mark drive flange (2) in relation to flyring (6), and fly-
ring (6) in relation to crankshaft (14). Unscrew hexa-
gon-head bolts (4) and pull off centring ring (5) from
flyring (6) and drive flange (2). Pull out split pins
(10), unscrew castellated nuts (9) with washers (17)
and take out of flyring (6) and drive flange (2).
Remove drive shaft (1).
A defective ring gear (8) can be removed and repla-
ced after unscrewing the hexagon-head bolts (7).
Use lifting tackle to hold flyring (6).
Fig. 1 Flyring (82593_0)
Take cover off gear casing. Unscrew hexagon-head
bolts (11) with washers (15), and take off threaded Refitment
pieces (12). Take flyring (6) off crankshaft (14). Give the contact surfaces of the parts to be fitted a
careful cleaning. When fitting flyring (6) in place,
make sure the markings are in their correct positi-
ons. To fit the disk, proceed in the opposite
sequence. Replace the split pins. Tightening instruc-
tions for the hexagon-head bolts (11) are provided in
Table 1.
Install drive shaft (1). Insert hexagon-head bolts (3)
with washers (16). Screw on castellated nuts (9)
with washers (17). Tighten hexagon-had bolts (3) as
specified in the tightening instructions, Table 1, and
secure with split pins (10).
© 0301 0299 6475-0125 JC 04 - Page 43

Engine control
04.09.02
Tightening instructions for bolts/nuts
Pre- Post-tightening angle [ ° ]

Pos. tightening Remarks
torque [Nm] 1st stage 2nd stage 3rd stage Total
Thread and head

3 240 -50 90 +-9 90 +-9 60 +-6 240 +-24 contact surface oiled
Head contact surface

11 240 -50 90 +-9 60 +-6 60 +-6 210 +-21 oiled, seal entire thread
with DEUTZ DW 48
Table 1
JC 04 - Page 44 0299 6475-0125 © 0301

Engine control
04.11.01
Crankshaft gear removal
Tools
- Standard tools
- Puller screws
Cross-references
- Job Card 02.17.01, 04.09.01, 04.09.02
Job
Remove locating bearing segments (3) (Job Card
02.17.01). Remove flywheel (Job Card 04.09.01) or
flyring (Job Card 04.09.02), as the case may be.
Unlock bolts (16) and unscrew. Withdraw supporting
ring (12) with oil retainer (13) from crankshaft (5).
Unlock bolts (11) and unscrew. Withdraw oil deflec-
tor (10) from crankshaft (5). Unlock bolts (8) and
unscrew. Take hood (9) out of the timing chest (18).
Unscrew bolts (1). Take plate (4) out of the timing
chest. Unlock bolts (2) and unscrew. Press crank-
shaft gear (6) by puller screws from the crankshaft
flange recess and carefully remove over the drive
flange.
For removing 0-seal (15), unlock bolts (14) and
unscrew. Pull off oil retainer (13) from support ring
(12). Take out 0-seal (15). Clean all components
and inspect.
Replace gasket (17).
Fig. 1 Crankshaft gear (83280_0)
© 0301 0299 6475-0125 JC 04 - Page 45

Engine control
04.11.01
JC 04 - Page 46 0299 6475-0125 © 0301

Engine control
04.11.02
Crankshaft gear refitment
Tools
- Standard tools
- Locking wire
Aids
- DEUTZ S2 compound
Cross-references
- Job Card 02.17.01, 04.06.02, 04.09.01,
04.09.02
Job
Apply DEUTZ S2 compound to flange recess. Care-
fully push crankshaft gear (6) into recess. Screw in
bolts (2) with locking plate and secure. Fit plate (4).
Screw in bolts (1) with washers. Install hood (9).
Lock bolts (8) by wire. Fit oil deflector (10) on driving
flange. Screw in bolts (11) with locking plates and
secure. Install new 0-seal (15). Assemble oil retai-
ner (13) and support ring (12). Lock bolts (14) by
wire.
Place support ring (12) with oil retainer (13) on
flange and, paying attention to dowel pins (7),
secure to timing chest (18) by bolts (16). Lock bolts
by wire.
Install bearing segments (3) (Job Card 02.17.01).
Attach flywheel (Job Card 04.09.01) or flyring (Job
Card 04.09.02), as the case may be.
Caution!
Following gear refitment check timing data
(Job Card 04.06.02).
Fig. 1 Crankshaft gear (83280_0)
© 0301 0299 6475-0125 JC 04 - Page 47

Engine control
04.11.02
JC 04 - Page 48 0299 6475-0125 © 0301

Engine control
04.14.01
Pump chest removal/refitment
Tools Aids
- Standard tools - DEUTZ DW 60 compound
- Eye screw - Surface-sealing Hylomar SQ 32/H
- Timber block
Cross-references
- Hoist
- Job Card 02.00.01, 08.04.01, 09.07.01
- Crowbar
Job
Removing the chest
Remove any oil pumps (Job Card 08.04.01) and
pipework with fittings. Fit eye screw (1) and attach to
hoist. Unscrew bolts (2) on chest periphery plus
bolts (7) securing chest (3) to oil pan (6). Hold tim-
ber block behind chest and carefully work loose
chest - left and right alternatively - by crowbar,
paying attention to dowel pins (5).
Note
Be sure not to damage any surfaces by the crowbar.
Remove chest (3) by hoist from oil pan (6) and put
down on wooden support.
Fig. 1 Pump chest (83281_0)
© 0301 0299 6475-0125 JC 04 - Page 49

Engine control
04.14.01
Refitting the chest

Clean and remove grease carefully from all sealing
surfaces. Polish any marks of impact on sealing sur-
faces carefully using a bastard file or oil stone.
Apply Hylomar SQ 32/H surface-sealing compound
on both sides of supporting surfaces for sealing of
pump chest (3) and crankcase as well as pump
chest and oil pan (6). Mount chest (3), taking care
that dowel pins (5) will locate the chest properly.
Screw in bolts (2) and bolts (7) with washers (8).
Insert the inside hexagon socket screws (4) with
DEUTZ DW 60 sealing compound, and tighten
them.
Unscrew eye screw (1). Reattach any removed oil
pumps and pipework. Inspect lubrication of gears on Fig. 2 Section A-B (83282_0)
adapter and of oil pump.
JC 04 - Page 50 0299 6475-0125 © 0301

Engine control
04.15.01
Auxiliary drive inspection/servicing
Tools
- Standard tools
- Dial gauge
- Feeler gauge
- Setting tool (Plate c/w bolts and nuts)
Cross-references
- Job Card 04.15.02, 05.00.01
Inspection/gauging
Inspect bevel gears and check backlash and flush-
ness “X” of bevel gears in auxiliary drive for speed
governor and tachogenerator.
Job
Remove cover (37) and housing (29) (Job Card
04.15.02). Inspect all gears including bevel gears
(7) and (8) plus bearings. Replace any defective
items.
Check backlash between (7) and (8) is 0.15 -
0.25 mm and that gears are flush at “X” (Fig. 3).
Failing this, gears or bearings are liable to be worn
and should be removed (Job Card 04.15.02) for
reconditioning and resetting as described below.
Servicing
Resetting the backlash
Remove auxiliary drive (Job Card 04.15.02). Fig. 1 Backlash (83283_0)
Slacken bolts (1) for a few turns. Remove thrust ring
Take out ring (19). Screw bolts (52) of setting tool
(18) from housing (4) by puller screws.
(Fig. 2) into bearing housing (24) and withdraw lat-
ter c/w motion parts from housing (4). Take out
shims (21). Reinstall bearing housing (24) with set-
ting tool into housing (4). Place dial gauge with
magnetic holder on housing (4). Place dial gauge
with magnetic holder on housing (4) so that gauge
sensor rests on bearing housing (24).
© 0301 0299 6475-0125 JC 04 - Page 51

Engine control
04.15.01
To ensure correct backlash and flushness “X”,

screw three M 8 bolts into bearing flange (2) and
move horizontal shaft gradually, while gradually
turning hex. nuts (53) and hence raising bearing
flange (24) until correct backlash and flushness are
simultaneously obtained.
Fig. 2 Governor (83284_0)
JC 04 - Page 52 0299 6475-0125 © 0301

Engine control
04.15.01
If no flushness “X” is achieved and if no clearance is

obtained at “e”, fit a replacement ring (5) and grind
down through the clearance measured at “e” by a
feeler gauge. Removal and refitment see Job Card
04.15.02. Tighten bolts (1) and lock.
The height adjustment of bearing housing (24), indi-
cated by the difference between “C” (Fig. 2) and “a”,
determines the thickness of shims (21). Any shim
(21) not required should be put on the flange of bea-
ring housing (24) to make thrust ring (18) flush with
housing (4). Install ring (19) and thrust ring (18) into
housing (4). Check that thrust ring (18) is flush with
the housing top edge.
Recheck backlash and flushness. Refit auxiliary
drive (Job Card 04.15.02).
a = depth of bearing housing (24)
b = height of thrust ring (18)
c = depth without shims (21)
© 0301 0299 6475-0125 JC 04 - Page 53

Engine control
04.15.01
JC 04 - Page 54 0299 6475-0125 © 0301

Engine control
04.15.02
Auxiliary drive removal/refitment
Tools
- Standard tools
- Puller screws
- Locking wire
- Setting tool
Aids
- Surface-sealing Hylomar SQ 32/H
Cross-references
- Job Card 05.04.01 resp. 05.04.11,
04.08.01
Removing the drive Remove governor (17) (Job Card 05.04.01). Discon-
Remove cover (37). Drain oil form housing (4). If dirt nect oil line (20). Unscrew waisted bolts (9) and (39)
and/or metal abrasive is discovered in the oil sump, and take down auxialiary drive from timing chest.
trace cause of trouble and remedy.
© 0301 0299 6475-0125 JC 04 - Page 55

Engine control
04.15.02
Dismantling the drive Refitting the drive

Remove thrust ring (18) form housing (4) by puller Clean and remove grease from sealing surfaces
screws. Take out ring (19). Screw bolts (52) of set- (50) on auxiliary drive and gear drive. Coat both
ting tool (Job Card 04.15.01) into bearing housing sealing surfaces (50) with Hylomar SQ 32/H sur-
(24) and withdraw housing (24) c/w motion parts face-sealing compound. Screw auxiliary drive on to
from housing (4). gear drive. Screw in waisted bolts (9) and (39) com-
Caution! plete with washers (10) and tighten through
236 Nm. Check backlash of gear (44) (Job Card
Rings (19) and (21) must be refitted in origi- 04.08.01).
nal quantity and sequence.
Fit new gasket (14) and mount governor (17) (Job
Unscrew bolts (22) and nut (32). Take down housing Card 05.04.01). Connect lube oil line (20).
(29) c/w mounted units like tachogenerator and
pressure booster. Remove plate (26), gear (28), key Test auxiliary drive and governor for proper opera-
(27). Unlock and unscrew bolts (1). Remove bearing tion.
flange (2) by three M 8 screws from housing (4) and
take out flange (2) c/w shaft (35) from housing (4).
Withdraw centering ring (34) c/w ball bearing (33)
from housing (4). Take down tube (36), bevel gear
(7), key (6) and ring (5) from shaft (35).
For replacing bearing (48), remove gear (44),
unlock bolts (46) and unscrew. Take down thrust
ring (47). Remove grub screw (41) and unscrew nut
(45). Take down ring (40). Pull off bearing (48) from
shaft (35).
Reassembling the drive
Clean all components and replace worn items.
Fit bearing (48) on shaft (35). Fit ring (40), nut (45)
and grub screw (41). Install shaft (35) into bearing
flange (2). Fit thrust ring (47). Screw in bolts (46)
and lock by wire. Install ring (5) (new ring, if neces-
sary), key (6) and bevel gear (7) on shaft (35). Intro-
duce bearing flange (2) with shaft (35) into housing
(4).
Lock bolts (1) by wire. Fit gear (44) and plate (42).
Screw in waisted bolt (43) and tighten through
157 Nm. Fit tube (36), ball bearing (33) with cen-
tering ring (34), key (27) and gear (28) on shaft (35).
Screw in waisted bolt (25) with plate (26) and tigh-
ten through 157 Nm.
Clean and remove grease from sealing surfaces
(49) of housings (4) and (29). Coat both sealing sur-
faces (49) with Hylomar SQ 32/H surface-sealing
compound. Screw housing (29) on to housing (4),
centered by ring (34).
Install shims (21). Insert shaft (16) with ball bearings
(12) and (15) plus bearing housing (24). Fit ring (19)
and thrust ring (18). Check that thrust ring (18) is
flush with housing (4). Check gear backlash and
flushness “X” (Job Card 04.15.01) and adjust as
necessary.
JC 04 - Page 56 0299 6475-0125 © 0301

Governor
05.00.01
Safety precautions (Speed control system)
General safety precautions Following work

When carrying out work on engine control unit, Open shut-off valves (4) on air receivers (5).
injection pump, governor and linkage, the following When putting the engine back to service, have an
precautions must be taken. assistant available at emergency stopping lever (6)
Prior to work (see also item 3 in Job Card 05.04.03): should the
Stop engine. Close shut-off valves (4) on air recei- engine tend to race, the lever must be pressed
vers (5) and exhaust feed air pipe to starting air down immediately.
master valve (2).
© 0301 0299 6476-0125 JC 05 - Page 1

Governor
05.00.01
JC 05 - Page 2 0299 6476-0125 © 0301

Governor
05.00.01
Safety precautions, speed control system Alstom Regulateurs Europa

hydraulic governor
If work is to be carried out on a speed governor,

engine control unit, governing linkage and injection
pump, strictly observe the following safety precauti-
ons:
Prior to work
Stop engine. close shut-off valve (2) on air receivers
(1). Bleed air supply line (3) to starting air master
valve (4).

Following work
Open shut-off valves (2) on air receivers (1). Should
the engine tend to race on starting, press stopping
button (5).
© 0301 0299 6476-0125 JC 05 - Page 3

Governor
05.00.01
JC 05 - Page 4 0299 6476-0125 © 0301

Governor
05.01.01
Engine control unit
Note
For operating and maintenance instructions on local
and remote control units see separate manual.
© 0301 0299 6476-0125 JC 05 - Page 5

Governor
05.01.01
JC 05 - Page 6 0299 6476-0125 © 0301

Governor
05.02.01
Governor action checking
Tools
- Standard tools
Cross-references
- Job Card 04.15.01, 05.00.01, 05.03.01,
05.03.02, 05.04.04, 07.02.02, 07.08.01
Checking Hunting
When the hydraulic governor provided performs Check governing linkage for free movement, pneu-
unsatisfactoriy, carry out the checks below. matic speed control valve for absence of impurities
Note and that governor oil viscosity is not too high. If hun-
ting cannot be remedied by changing the setting or
Normally, there are two types of governor/speed should the governor fail completely, have governor
irregularities: high-frequency “jiggling” (10 or more replaced or reconditioned by mechanics fully con-
oscillations per second) or low-frequency “hunting” versant with this job, and strictly in accordance with
(2 or less oscillations). the instructions of the governor manufacturer.
Job Further causes of governor jiggling or hunting may
Observe safety precautions (Job Card 05.00.01). be found in coupling, gearing, shafting, propeller or
other driven equipment.
Jiggling
When jiggling occurs, especially at idling speed,
take indicator diagrams to see whether all cylinders
work properly and there is no misfiring, or whether
injectors (Job Card 07.08.01) or injection pump deli-
very valves (Job Card 07.02.02) are fefective, or the
emergency governor spring is too weak. Then
check governor drive gears for correct backflash
and governing linkage for correct clearance.
© 0301 0299 6476-0125 JC 05 - Page 7

Governor
05.02.01
Full checking details are given as follows:

- Check governor oil level and condition. If neces-
sary, change oil (Job Card 05.03.01).
- Check linkage between governor and injections
pumps. Links, rod, shafts, joints etc. must move
freely but without undue slackness. Check tight-
ness of brakket for spring rod arm on auxiliary
drive and of bolts securing levers, couplings etc.
(Job Card 05.04.04).
- Check that speed irregularities are not due to
engine overload.
- Check speed control units (pneumatic or electric,
as provided) for freedom from defects and for-
eign particles.
- Check needle valve and compensation adjust-
ment for correct position (Job Card 05.03.02)
respectively.
- Check governor drive for correct clearance
(Job Card 04.15.01).
JC 05 - Page 8 0299 6476-0125 © 0301

Governor
05.03.01
Hydraulic governor servicing (Woodward PG 16)
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.03.02
Servicing Note
Change oil, if contaminated. The amount of oil required for governor with pres-
Note sure booster and piping is approx. 1.5 litres.
Be sure to fill in fresh oil as specified by the

governor manufacturer, from perfectly clean contai-
ners. If necessary, clean containers with fresh gas
oil.
Oil change is possible with governor removed or
not. The old oil to be drained should be in hot condi-
tion.
Job
Stop engine in hot condition. Observe safety pre-
cautions (Job Card 05.00.01).
1. Open cock (6) and drain oil.
2. Close drain and fill in fresh oil through neck (1)
up to bottom mark of glass (5).
3. Unscrew bolt (3). Remove filler, inspect and
clean. Reinstall filter and screw bolt (3) back in
place.
4. Run engine for a few minutes, drain scavenging
oil and close drain.
5. Fill in fresh oil again up to lower mark. Check
that in service the oil level is in the middle of the
inspection glass.
Caution!
If necessary, top up to this level but do not Fig. 1 Hydraulic governor (83289_0)
overfill!.
6. If governing troubles occur in service, adjust
needle valve (6) (Job Card 05.03.02).
© 0301 0299 6476-0125 JC 05 - Page 9

Governor
05.03.01
JC 05 - Page 10 0299 6476-0125 © 0301

Governor
05.03.01
Hydraulic governor servicing (Woodward UG 40)
Tools
- Standard tools
Aids
- DEUTZ F5 gear grease
Cross-references
- Job Card 05.00.01, 05.03.02
Servicing
Change oil, if contaminated, and change grease.
Note
Be sure to fill in fresh oil as specified by the
governor manufacturer, from perfectly clean contai-
ners. If necessary, clean containers with fresh gas
oil.
Oil change is possible with governor removed or
not. The old oil to be drained should be in hot condi-
tion.
Job
Stop engine in hot condition. Observe safety pre-
cautions (Job Card 05.00.01).
Changing oil of governor in situ
1. Unscrew plug (5) and drain oil.
2. Refit plug (5) and fill in fresh oil through neck
(13) up to bottom mark of glass (1).
3. Run engine for a few minutes, drain scavenging
oil and close drain.
4. Fill in fresh oil again up to lower mark. Check
that in service the oil level is in the middle of the
inspection glass.
Caution!
If necessary, top up to this level but do not
overfill!.
5. If governing troubles occur in service, adjust
needle valve (6) (Job Card 05.03.02).
Fig. 1 Hydraulic governor (83290_0)
© 0301 0299 6476-0125 JC 05 - Page 11

Governor
05.03.01
Changing oil of governor removed

- Remove cover (5) with speed control motor.
- Drain oil by turning governor upside down.
- Flush governor with fresh oil until all impurities
are removed.
- Fill governor with fresh oil, fit cover (4) and
mount governor.
- If necessary, top up as with governor in situ.
Changing gear grease
Remove gearing (2) from governor and wash out old
grease with gas oil. Fill in fresh DEUTZ F5 grease to
3/4 capactiy.
JC 05 - Page 12 0299 6476-0125 © 0301

Governor
05.03.02
Hydraulic governor setting (Woodward PG 16)
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.02.01, 05.03.11
Setting
Following governor action checking (Job Card
05.02.01) or a change of the governor oil (Job Card
05.03.11), the compensation (needle valve) needs
adjustment (see also manufacturers’ instructions).
Note
When sudden load changes result in heavy over- or
underspeeding and sluggish return to the preset
speed, this suggests wrong needle valve setting.
Job
When engine and governor oil temperatures have
reached their working level, proceed as follows:
- Unscrew plug (1).
- Open needle valve behind through 2 or 3 turns
by screwdriver.
- Run engine for 30 seconds or so in order to
bleed the governor passages.
- If engine speed is irregular, turn needle valve
clockwise until engine runs smootly.
Note
Check that needle valve is not fully closed. As a
check-up on this, vary engine speed or load: speed
must quickly return to the preset level without
unduly great oscillations. (normally it will be suf-
ficient to open needle valve from closed position Fig. 1 Hydraulic governor (83291_0)
through half a turn).
- Refit plug (1).
© 0301 0299 6476-0125 JC 05 - Page 13

Governor
05.03.02
Note
Depending on this particular installation, the follo-
wing thumb rule will apply:
- needle valve almost closed: load changes will
cause heavier transient speed changes, but little
tendency to hunting.
- needle valve fully open: tendency to hunting is
great, but following load changes the speed will
return to ist preset value soon.
JC 05 - Page 14 0299 6476-0125 © 0301

Governor
05.03.02
Hydraulic governor setting (Woodward UG 40)
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.03.01
Setting - Let engine “hunt” for half a minute or so in order

Following a change of the governor oil (Job Card to bleed the governor passages.
05.03.01), the compensation (needle valve) may - Turn needle valve clockwise until hunting is just
need adjustment (see also Woodward instructions). about to cease. Check that valve is open through
Note min. 3/8 turn. Failing this, set adjusting pointer
gradually higher and repeat procedure until opti-
When sudden load changes result in heavy over- or mum setting has been attained. As a check-up
underspeeding and sluggish return to the preset on this, vary engine speed or load. Speed must
speed, this suggests wrong compensation setting. quickly return to the preset level without unduly
Job great transient speed variations.
Caution!
When starting the engine and during trial run
be sure to observe the Safety Precautions
(Job Card 05.00.01).
When engine temperature and governor oil tempe-
rature have reached their working level, adjust com-
pensation preferably at lowest engine lad and speed
as follows:
- Release nut on compensation adjusting pointer
(1). Set pointer to bottom stop “MIN” and retigh-
ten nut.
- Remove plug (2) and open needle valve behing
through 2 or 3 turns with a screwdriver of 6.5 mm
width.
Caution!
Put screwdriver into flat slot of needle valve,
not into the deep one !
© 0301 0299 6476-0125 JC 05 - Page 15

Governor
05.03.02
Note
Depending on the particular installation, the follo-
wing thumb rule will be applicable: A raise of the
pointer setting will result in larger transiet speed
changes as load is changed, but will cause a lower
governor hunting; larger transient speed changes as
load is changed, but will cause a lower governor
hunting; larger opening of the needle valve will, on
the other hand, cause more governor hunting, but
quicker return to the preset speed following load
changes. Usually, the optimum setting will be as fol-
lows:
Stationary engines
Needle valve opening between 1 and 1 1/2 turn -
adjusting pointer between “MIN” and mid-scale.
Marine propulsion engines
Needle valve opening between 1/2 and 3/4 turn -
adjusting pointer at “MIN”.
Note
The governor speed droop is preset by the manu-
facturer to suit the particular engine application and
must not be changed by the engine user.
JC 05 - Page 16 0299 6476-0125 © 0301

Governor
05.03.04
Hydraulic governor reconditioning (Woodward PG 16)
Cross-references
- Job Card 05.00.01, 05.04.01
Reconditioning
Normally, this job should be entrusted to Woodward.
Should an emergency call for local reconditioning,
the Woodward set of instructions must be strictly
observed.
Note
For governor removal/refitment see Job Card
05.04.01.
© 0301 0299 6476-0125 JC 05 - Page 17

Governor
05.03.04
JC 05 - Page 18 0299 6476-0125 © 0301

Governor
05.03.04
Hydraulic governor reconditioning (Woodward UG 40)
Cross-references
- Job Card 05.00.01, 05.04.01
Reconditioning
Normally, this job should be entrusted to Woodward.
Should an emergency call for local reconditioning,
the Woodward set of instructions must be strictly
observed.
Note
For governor removal/refitment see Job Card
05.04.01.
© 0301 0299 6476-0125 JC 05 - Page 19

Governor
05.03.04
JC 05 - Page 20 0299 6476-0125 © 0301

Governor
05.03.11
Hydraulic governor servicing (Alstom Regulateurs Europa)
Tools
- Standard tools
Cross-references
- Job Card 05.03.12
Servicing (Oil Change)

Change oil when contaminated and also when
governor is removed from engine since this allows
for especially thorough cleaning.
Note
Be sure only to use fresh oil as specified by the
governor manufacturers.
Oil change is possible with governor mounted on
the engine. The old oil is drained in hot condition.
Before filling in new oil check that the vessels used
are clean. If necessary, wash them in clean gas oil.
Caution!
During trial run and starting make sure that
the injection pump control rod(s) can be
immediately moved to no-load once the
engine should start racing.
Job
Stop engine in hot condition
1. Unscrew plug (2) and drain oil.
2. Close drain plug and fill in fresh governor oil
through neck (1) with strainer until level reaches
inspection glass.
3. Run engine for a few minutes and stop.
4. Drain scavenging oil and close drain (2).
5. Fill in fresh governor oil up to inspection glass
(3).
Caution! Fig. 1 Hydraulic governor (25572_0)
If necessary, top up oil in service but do not
overfill!
6. Adjust needle valve (Job Card 05.03.12), but
only when engine speed is irregular in service.
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Governor
05.03.011
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Governor
05.03.12
Hydraulic governor setting (Alstom Regulateurs Europa)
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.03.11
Setting After restoring the original governor setting, the fol-

Following a check on governor action (Job Card lowing will apply.
05.02.01) or a change of the governor oil (Job Card - If engine speed is still irregular, close needle
05.13.11), the compensation (needle valve) needs valve clockwise until engine runs smoothly. (Be
adjustment (see also the manufacturers’ instruc- sure, however, the needle valve stays open for at
tions). least half a turn.)
Note - Refit plug (1).
When sudden load changes result in heavy over- or - If the speed remains constant, stop engine and
underspeeding and sluggish return to the preset check that needle valve is open for at least half a
speed, this suggests wrong needle valve setting. turn.
Job - Refit plug (1).
Caution!
When starting the engine and during trial run
be sure to observe the Safety Precautions
(Job Card 05.00.01).
When engine and governor oil temperatures have
reached their working level, proceed as follows:
- Unscrew plug (1).
- Open needle valve behind through 2 or 3 turns
by screwdriver.
- Run engine for 30 seconds or so in order to
bleed the governor passages. In this process,
the speed may vary.
© 0301 0299 6476-0125 JC 05 - Page 23

Governor
05.03.12
Note
Except for departures due to the different installati-
ons, the following thumb rule will apply:
- With the needle valve almost closed, changes of
the load will cause higher transient speed oscilla-
tions, while there is little tendency of the
governor to hunt.
- With the needle valve open, there will be a grea-
ter tendency to governor hunting, while load
changes cause only little transient speed chan-
ges.
Note
The governor speed droop is preset by the manu-
facturer to suit the particular engine application and
must not be adjusted by the engine user.
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Governor
05.03.14
Hydraulic governor servicing/reconditioning (Alstom Regulateurs Euro-

pa)
Servicing/reconditioning
Any servicing or reconditioning work on the
“Europa” governor should be caried out strictly in
accordance with the manufacturers’ instructions or
preferably by the manufacturers themselves.
Note
Before removing governor form engine, mark con-
nections.
Any loss of oil requiring replensishment more than
once a week should be eliminated by replacing
governor drive shaft seal (1) according to the manu-
facturers’ instructions.
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Governor
05.03.14
JC 05 - Page 26 0299 6476-0125 © 0301

Governor
05.04.01
Hydraulic governor removal/refitment (Woodward PG 16)
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.03.01, 05.03.02,
05.04.04
Job
Removing the governor
Disconnect all piping interfering with removal of
governor (6) plus control oil piping (5), starting pres-
sure booster piping and pipe to charge air passage.
Open plug (7) and drain oil. Close cock. Withdraw
plug (4) with wire terminal.
Detach fork lever (2) from governor by pulling split
pin out of lever pin, taking off the washer and with-
drawing pin from fork (1).
Unscrew bolts (8). Remove governor (6) from auxi-
liary drive. Blank off resultant aperture of auxiliary
drive.
Caution!
Do not put governor down on ist projecting
drive shaft, otherwise ball bearing, oil pump
etc. may become defective.
Refitting the governor
Clean joint faces between governor and auxiliary
drive. Place new gasket (3) on auxiliary drive. Then
mount governor, taking care that ist drive shaft will
smootly slide into the hollow auxiliary drive shaft.
Screw nuts (8) in place and evenly tighten cross-
wise.
Connect fork lever (2) to fork (1) by inserting pin, fit- Fill governor with oil (Job Card 05.03.01) and bleed.
ting washer and locking by split pin. Connect control Observe safety precautions (Job Card 05.00.01).
oil piping (5), starting pressure booster oil piping Start engine and check that governor works pro-
and air pipe to charge air passage. Couple up plug perly. Check setting of governor (Job Card
(4). 05.03.02) and linkage (Job Card 05.04.04).
Start engine and check that governor works pro-
perly.
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Governor
05.04.01
JC 05 - Page 28 0299 6476-0125 © 0301

Governor
05.04.01
Hydraulic governor removal/refitment (Woodward UG 40)
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.03.01, 05.03.02,
05.04.04
Job
Removing the governor
Disconnect all piping interfering with governor (7)
removal. Unscrew plug (6) and drain oil. Refit plug.
Disconnect wire from speed control motor (1).
Detach linkage: Take out circlip (5), press out pin (2)
and remove spring rod (3) from clamping lever (4).
Caution!
Detachment of lever (4) from governor is
permissible only for replacing the governor.
Unscrew nuts (8) of the four studs and remove
governor (7) from auxiliary drive along with gasket
(9).
Caution!
Do not put governor down on ist projecting
drive shaft, otherwise ball bearing, oil pump
etc. may become defective.
© 0301 0299 6476-0125 JC 05 - Page 29

Governor
05.04.01
Refitting the governor

Clean joint faces between governor and auxiliary
drive. Place new gasket (9) on auxiliary drive.
Thereupon place governor, taking care that
governor drive shaft will smoothly slide into the hol-
low auxiliary drive shaft. Screw nuts (8) in place and
evenly tighten crosswise.
Attach spring rod (3) to clamping lever (4) and
secure pin (2) by circlip.
Connect wire to motor (1). Fill governor with clean
and correct type of oil (Job Card 05.03.01). Observe
safety precautions (Job Card 05.00.01).
Set governor (Job Card 05.03.02) and linkage (Job
Card 05.04.04).
Start engine and check that governor works pro-
perly.
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Governor
05.04.02
Governing linkage removal/refitment, In-line engine
Tools
- Standard tools
- 5 mm dia. drift punch
Cross-references
- Job Card 05.04.03, 05.04.04, 05.04.05,
07.04.01
Removing the linkage

Remove injection pumps along with plunger control
mechanisms (Job Card 07.04.01). Detach any inter-
fering piping and access hole covers (8) from cam-
shaft carrier cases (7).
Fig. 2 Pick-up arm (25436_0)

Releasing stop arm (12)
Remove locking wire (14). Slacken nut (11) and turn
adjusting screw (15) so dowel sleeve (13) comes
free and can be driven out by punch from stop arm
(12). Unlock bolt (16) and unscrew (section E-F).

Removing pick-up arm (1)
Detach spring rod (4) from pickup arm (1). To do
this, take circlip from pin (3) and drive pin out.
Unlock bolt (5) and unscrew.
Drive out dowel pin (2) by punch. Pull off pick-up
arm (1) from control rod (6).
© 0301 0299 6476-0125 JC 05 - Page 31

Governor
05.04.02
Fig. 5 Section C-D (83299_0)

Removing bearing housing (24)
Remove housing (24) along with control rod (6) out
Removing lever (17)
of camshaft carrier cases (7).
Remove screws (18). Take down lever (17) with cup
springs (19) and dowel sleeve (20) from control rod
(6). (section A-B).
Fig. 6 Bearing housing (83300_0)

Removing emergency stopping lever “X”
Remove hollow screw (39) with spring (38) and ball
(37) (section G-H).
Parting clamping couplings (22)
Release screw (35). Pull off actuating plate (27)
Note:Couplings are provided on: from control rod (6). Take down key (26). Pull off
6-cyl. engines between cylinders No. 3/4 stop plates (36) and stopping lever (33). Remove
screws (29) and take down flanged bearing (28).
8-cyl. engines between cylinders No. 3/4 and 6/7
If necessary, drive dowel sleeve (31) and remove
Drive dowel pin (23) by punch out of coupling (22).
stop ring (30).
Remove screw (21) (section C-D).
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Governor
05.04.02
Fig. 7 Governing linkage (83301_0)
© 0301 0299 6476-0125 JC 05 - Page 33

Governor
05.04.02
Where engine is direct-reversing, remove camshaft

reversing oil reervoir (Job Card 04.07.03). Remove
control half-rods toward engine free end. Take out
couplings (22) and stop arm (12) from camshaft car-
rier cases (7).
Clean all components and inspect for wear. Replace
any defective items. Renew 0-seals (25) and (32).
Refitting the governing linkage
Introduce control rods (6) from the engine’s free end
into camshaft carrier cases (7). In doing so, fit stop
arm (12).
Fit couplings (22). Tighten screws (21) through
69 Nm (section C-D).
Fit stop arm (12). Insert new dowel sleeves (13).
Secure hex. bolt (16) (section E-F).
Fit lever (17). To do this, install dowel bush (20) into
control rod (6). Tighten lever by screw (18) and cup
springs (19) (section A-B).
Fit pick-up arm (1) to control rod (6) and link to
spring rod (4). Lock bolt (5) by plate.
If removed, install stop ring (30) with new dowel
sleeve (31). Introduce flanged bearing (28) with new
0-seal (32) on control rod (6) into camshaft end
case, paying attention to dowel pin (34), and secure
by screws (29). Install lever (33) with stop washers
(36). Install key (26). Fit actuating plating (27) and
clamp down by screw (35) on control rod (6) (detail
“X”).
Fit hollow screw (39) with spring (38) and ball (37)
(section G-H).
Check that between stop ring (30) and flanged bea-
ring (28) there is a clearance of a = 0.5 +- 0.2 mm.
Set adjusting screw (15) on stop arm (12) (Job Card
05.04.01).
Install injection pumps (Job Card 07.04.01).
Inspect governing linkage (Job card 05.04.03).
Mount access hole covers and removed piping.
Check setting of governor to linkages (Job Card
05.04.04).
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Governor
05.04.02
Governing linkage removal/refitment, V-type engine
Tools
- Standard tools
- 5 mm dia. drift punch
Cross-references
- Job Card 04.07.03, 05.04.03, 05.04.04,
05.04.05, 07.04.01
Removing the linkage

Remove injection pumps (Job Card 07.04.01).
Detach any interfering piping and access hole
covers (15) from camshaft carrier cases (14).
Parting links (1) from governing linkage
To keep toothed segments (3) of links (1) in mesh,
tie links together by wire (2).

RH engine side (B-Side)
Detach spring rod (11) from pick-up arm (8). To do
this, take circlip from pin (12) and drive pin out
Unlock bolt (9) and unscrew. Drive out dowel pin
(10) by punch. Pull off pick-up arm (8) from control
rod (13).
LH engine side (A-Side)
Take circlip from pin (5) and press pin out of lever
(4). Drive out dowel pin (6) by punch. Unlock nuts
(7) and unscrew. Withdraw lever (4) from control rod
(13).
© 0301 0299 6476-0125 JC 05 - Page 35

Governor
05.04.02
Fig. 4 Pick-up arm (25568_0)

Releasing stop arm (17) Removing lever (22)
Remove locking wire (19). Slacken nut (16) and turn Remove screws (23). Take down lever (22) with cup
adjusting screw so dowel sleeve (18) comes free springs (24) and dowel sleeve (25) from control rod
and can be driven out by punch from stop arm (17). (13) (section A-B).
Unlock bolt (21) and unscrew (section E-F).
JC 05 - Page 36 0299 6476-0125 © 0301

Governor
05.04.02
Drive dowel pin (28) by punch out of coupling (27).

Remove screw (26) (section C-D).

Parting clamping couplings (27)
Note:Couplings are provided on
- 12-cyl. engines between cylinders A3/A4 and Fig. 7 Section C-D (83436_0)
B3/B4 Removing bearing housing (29)/(30)
- 16-cyl. engines between cylinders A3/A4, A6/A7, Remove housings (29) and (30) respectively along
B3/B4 und B6/B7. with control rod (13) out of camshaft carrier case
(14).
Fig. 8 Bearing housing (83437_0)
© 0301 0299 6476-0125 JC 05 - Page 37

Governor
05.04.02

Removing emergency stopping lever “X” Caution!
Remove hollow screw (47) with spring (46) and ball Toothed segments (3) must never be out of
(45) (section G-H). mesh. Should they accidentally become
Release screw (44). Pull off actuating plate (35) disengaged, take care that, when reenga-
from control rod (13). Take down key (34). Pull off ging them, the central tooth of the RH seg-
stop plates (48) and stopping lever (42). Remove ment will mate the gap of the LH segment.
screws (37) and take down flanged bearing (36). Mount emergency stopping lever “X”. Install new
If necessary, drive out dowel sleeve (39) and dowel sleeve (39). Check that between stop ring
remove stop ring (38). (38)/(33) and flanged bearing (36) / bearing housing
(30) there is a clearance of a = 0.5 +- 0.2 mm.
Remove camshaft reversing oil reservoir (Job Card
04.07.03). Remove control half-rods toward engine Set adjusting screw (20) on stop arm (17) (Job Card
free end. Take out couplings (27) and stop arm (17) 05.04.05).
from camshaft carrier cases (14). Install injection pumps (Job Card 07.04.01).
Clean all components and inspect for wear. Replace Inspect governing linkage (Job Card 05.04.03).
any defective items. Renew O-seals (31) and (40).
Mount access hole covers and any removed piping.
Refitting the governing linkage
Check setting of governor to linkage (Job Card
Introduce control rods (13) from the engine free end 05.04.04).
into camshaft carrier cases (14). On the LH engine
side put stop arm (17) in place while introducing rod
(13). Fit couplings (27). Tighten screws (26) through
69 Nm torque.
Secure stop arm (17). Use only new dowel sleeves
(18) and (32).
Fit lever (22).
Put pick-up arm (8) on control rod (13) and attach to
spring rod (11). Couple links (1) to control rod.
Secure bolts (7) and (9) by plates. Remove wire (2).
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Governor
05.04.03
Governing linkage inspection
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.04.02, 05.04.04
Inspection Move emergency stopping lever (3) on control rod

Inspect linkage for free movement and freedom (1) up (“FULL”) and down (“Stop”) several times so
from wear in joints and bearing bushes. that the plungers of the injection pumps turn within
the entire control range. Check the linkage for easy
Job movement.
Observe safety precautions (Job Card 05.00.01). If joints of spring rod and levers and/or bearing bus-
For detaching linkage, disconnect spring rod (11) hes are worn, dismantle linkage (Job Card
from pick-up arm (8) (Job Card 05.04.02). 05.04.02) and recondition.
Caution! Following inspection, reattach linkage to governor,
provide correct setting (Job Card 05.04.04) and
Do not excercize brute force on the
inspect stop arm assembly of control rod (Job Card
governor!
05.04.05).
© 0301 0299 6476-0125 JC 05 - Page 39

Governor
05.04.03
JC 05 - Page 40 0299 6476-0125 © 0301

Governor
05.04.04
Governor linkage setting (Woodward PG 16)
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.04.01, 05.04.03
Checking
Check setting of governing linkage.
Job
If necessary, inspect linkage (Job Card 05.04.03)
and recondition.
Open air receiver shut-off valve with engine control
lever in “Stop” position, which will also move pneu-
matic injection pump on/off control (1) to “off”
(“Stop”) position. Check that clearance “X” between
pin (9) of on/off control (1) and pick-up arm (4)
should be 0.5 + 1 mm (V-type engine) resp. no more
than 0.1 mm (In-line engine). If necessary, vary
thickness of shim pack (2).
© 0301 0299 6476-0125 JC 05 - Page 41

Governor
05.04.04
Fig. 1 Governor, In-line engine (83303_0)
Fig. 2 Governor, V-type engine (83440_0)
JC 05 - Page 42 0299 6476-0125 © 0301

Governor
05.04.04
Settings after reconditioning

Described hereunder are linkage adjustments for
three alternative reconditioning situations.
I Governor (3), or link (7) or lever (8) or spring rod
(5) has been removed/refitted or replaced.
II Pick-up arm (4) has been replaced.
III Control rod (11) has been replaced.
Job
I
Mount governor (3) (Job Card 05.04.01) and
attach the entire linkage. Adjust link (7) in length
so that - as described under CHECKING - the
settings of linkage and on/off control (1) are cor-
rect. To do this, release clamping devices from
linkage (7) and vary the length by turning the
grub screw by means of hexagon (13). Fig. 3 Governor (83302_0)
II Observe safety precautions (Job Card 05.00.01). By
Since control rod (11) and pick-up arm (4) have means of emergency stopping lever (17) (Fig. 3),
already been jointly drilled, fit all components, turn control rod (11) until the acceptance test rea-
drive in dowel pin (10) and lock lever (4) by bolt dings under “Stop” position. Fit pick-up arm (4) to
(12). Secure bolt in turn by plate. control rod (11) so that it contacts pin (9) of on/off
III control (1). In this position drill control rod (11) and
pick-up arm (4) together and drive home dowel pin
Following replacement of control rod (11) (Job (10). Finally treat linkage as described under
Card 04.06.01), linkage setting should preferably CHECKING and, if required, adjust.
be entrusted to a DEUTZ serviceman. Provided
pump on/off control (1) is fitted in its original con-
dition, the procedure is as follows:
© 0301 0299 6476-0125 JC 05 - Page 43

Governor
05.04.04
JC 05 - Page 44 0299 6476-0125 © 0301

Governor
05.04.04
Governor linkage setting (Woodward UG 40)
Tools
- Standard tools
- Lever for governor shaft 8 (Woodward)
Cross-references
- Job Card 05.00.01, 05.04.01, 05.04.03
Checking
Check setting of governng linkage.
Job
Set governor load limit knob “D” (Fig. 3) to gradua-
tion 10. By means of emergency stopping lever (15)
(Fig. 4) turn control rod (12) until governor load
pointer “C” (Fig. 3) shows to graduation 1. If neces-
sary, inspect linkage (Job Card 05.04.03) and
recondition.
Open air receiver shut-off valve with engine control
lever in “Stop” position, which will also move the
pneumatic injection pump on/off control (1) to the
“off” (“Stop”) position. This must cause control rod
(12) to turn the pump plungers until here, too, the
acceptance test readings as above are obtained. If
necessary, vary thickness of shim pack (2).
© 0301 0299 6476-0125 JC 05 - Page 45

Governor
05.04.04
Fig. 1 Governor, In-line engine (83304_0)
Fig. 2 Governor, V-type engine (83441_0)
JC 05 - Page 46 0299 6476-0125 © 0301

Governor
05.04.04
Settings after reconditioning Job

Described hereunder are linkage adjustments for I
four alternative reconditioning situations. Observe safety precautions (Job Card 05.00.01).
I Only governor (10) has been removed and refit- Mount reconditioned governor (10) (Job Card
ted. 05.04.01). Turn knob “D” to 10. Turn governor
II Either governor (10) has been replaced by the shaft (8) by Woodward lever until load indicating
same type, or spring rod (4) and/or clamping pointer “C” (Fig. 3) is at 1. Turn control rod (12)
lever (7) has been replaced. with emergency stopping lever (15) (Fig. 4).
Attach governing linkage. Secure clamping lever
III Pick-up arm (3) has been replaced. (7) by bolt (9) with locking plate. Finally test pro-
IV Control rod (12) has been replaced. per functioning of linkage as described under
CHECKING. Pay particular attention to on/off
control (1).

Caution!
In-line engine:
While adjusting the linkage, be sure clevis
(6) is contacting the stop of sleeve (5)
(Fig. 1) and spring rod (4) is not compres-
sed.
V-type engine:
While adjusting the linkage, be sure spring
rod (4) (Fig. 2) is always resting at its inside
stop.
© 0301 0299 6476-0125 JC 05 - Page 47

Governor
05.04.04
II
Set linkage as under “I”. Since the serrations of
governor shaft (8) on the old and the new
governor may differ in their location and in view
of the replacement of spring rod (4) or clamping
lever (7), accurate mounting of the linkage may
prove impossible. However, in order to avoid dril-
ling new holes in control rod (12) and pick-up
arm (3) for dowel pin (13), try to reduce the diffe-
rence as small as possible when assembling
lever (7) and shaft (8). With load indicating poin-
ter “C” (Fig. 3) at graduation 1, turn control rod
(12) by emergency stopping lever (15) (Fig. 4) as
little as possible - preferably toward less fuel
(Fig. 1/Fig. 2) - for being able to slip clamping
lever (7) over governor shaft (8). Then test lin-
kage as under CHECKING.
III
Since control rod (12) and pick-up arm (3) have
already been commonly drilled, fit components,
drive in dowel pin (13), secure pick-up arm (3) by
bolt (11) and lock by plate. Treat linkage as
under CHECKING and, if required, adjust as
under “II”.
IV
Following replacement of control rod (12) (Job
Card 05.04.02), linkage setting should should
preferably be entrusted to a DEUTZ serviceman.
Provided on/off control (1) is fitted in ist original
condition, the procedure is as follows:
However, leave air receiver shut-off valve open
with engine control lever in “Stop” position. The
resultant air flow will pull the pump on/off control
(1) to the “Stop” (off) position. By means of emer-
gency stopping lever (15) (Fig. 4), turn control
rod (12). Fit pick-up arm (3) to control rod (12)
(Fig. 1/Fig. 2) so that it contacts pin (14) of on/off
control (1). In this position drill control rod (12)
together with pick-up arm (3) and drive home
dowel pin (13). Attach governing linkage accor-
ding to I or II and check setting as under
CHECKING, especially as fas as on/off control
(1) is concerned.
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Governor
05.04.05
Injection pump stop arm (Load limit) setting
Tools
- Standard tools
- Lead seal with wire
Cross-references
- Job Card 05.00.01, 05.04.04
Servicing
Set stop arm when the linkage job is finished.
Note
The load limit values of load indicator “A” of the indi-
vidual injection pumps are given in the acceptance
test sheets under “limit”.
Job
Check setting of linkage (Job Card 05.04.04).
6/8-cyl. engine
By means of emergency stopping lever (7), adjust
control rod (6) so that the load limit values of the
individual injection pumps correspond on average Fig. 1 Stop arm (83307_0)
with the acceptance test load limit values. If requi-
red, loosen nut (1) and turn adjusting screw (5) until
it contacts stop (3). Retighten nut (1) and secure by
wire (4). Start engine and upon attainment of wor-
king temperatures put on load until control rod rea-
ches ist load limit (stop arm). Compare readings
with acceptance test sheets and, if necessary,
adjust load limit.
12/16-cyl. engine
Set stop arm (load limit) of RH engine side as des-
Fig. 2 Stop arm (25531_0)
cribed for 6/8-cyl. models. Turn control rod (6) of this
side counter-clockwise against stop (3) (load limit)
and secure. Turn control rod on the LH engine side
equally counter-clockwise (no-load direction) until
the clearance in the control rod linkage is removed.
Turn adjusting screw (5) until it contacts stop (3).
Tighten nut (1) and lock by wire (4).
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Governor
05.04.05
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Governor
05.04.06
Hydraulic governor controls (Woodward PG 16)
Explanation on manual speed changer (1) (emer-

gency adjustment) at the PG 16 governor.
Wheel (1) is provided for varying speed within the
normal range, which is especially important for
emergency situation, e.g. should the pneumatic
system fail.
Fig. 1 Governor (PG16) (83308_0)
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Governor
05.04.06
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Governor
05.04.06
Hydraulic governor controls (Woodward UG 40)
Legend for controls of dial-type governor

1) Speed droop
2) Load limit
3) Synchronizer
4) Syn. Indicator
Knob (1) - Speed droop
- Single operation of engines
Selection of permanent speed deviation between
no-load and full load. If speed droop is reduced
to zero, an engine load change does not involve
a speed change.
- Parallel operation of engines
Even distributuion of load among engines wor-
king on one shaft or working in parallel in an
electric system.
The speed droop is preset by the manufacturer
to suit the particular application and is checked
at the engine’s factory test run.
Note
Never change the preset speed droop.
Knob (2) - Load limit
This knob reduces engine load mechanically and
hydraulically by reducing the governor shaft angle of
rotation. Also, the maximum quantity of fuel fed to
the engine is decreased. Turning the knob to zero Fig. 1 Governor (UG 40) (83309_0)
will stop the engine.
Caution!
Always turn load limit knob to 10 before
moving the governing linkage in the maxi-
mum fuel direction.
© 0301 0299 6476-0125 JC 05 - Page 53

Governor
05.04.06
Knob (3) - Synchronizer (Speed Control)

This knob is provided for direct speed control on the
engine. An electric speed control motor in the
governor permits remote speed variation.
Knob (4) - Synchr. Indicator
Knob (4) is fixed. The disc behind the knob includes
a pointer which moves through one graduation for
each full turn of knob (3) and hence gives an indirect
indication of the prevailing speed.
Note
For further details on this governor and parallel ope-
ration of engines see Woodward literature.
JC 05 - Page 54 0299 6476-0125 © 0301

Governor
05.07.01
Pneumatic injection pump fuel on/off control servicing
Tools
- Standard tools
Aids
- Compound DEUTZ S2
Cross-references
- Job Card 05.00.01, 05.04.04
Servicing
Remove, inspect and clean the fuel on/off control
ram (engine shutdown device).
Removing the on/off control
Disconnect air piping from on/off control. Drive out
dowel sleeve (7) by punch. Unscrew bolt (16) and
remove control ram from engine. Take shim pack
from bracket and store carefully.
Dismantling the on/off control
Unscrew screws (8). (Cautions: cover (1) is spring-
loaded!) Take down cover (1) and remove spring
(3). Push piston (4) with rod (6) out of cylinder (5).
Unscrew nut (10). Pull rod (6) out of piston (4).
Clean all components and inspect. Replace V-seal
(11) of piston (4) and - after removing circlip (13) - V-
seal (14) in housing (5). Replace 0-seals (2) and
(12). Inspect scraper (17) and replace if required.
Fig. 1 Pneumatic injection pump on/off control

(833010_0)
© 0301 0299 6476-0125 JC 05 - Page 55

Governor
05.07.01
Reassembling the on/off control

Before reinstalling V-seal (14), check that washer
(15) is present in housing (5). Fit circlip (13).
Slightly apply DEUTZ S2 to rod (6), piston (4) and
running surface of cylinder (5).
Push rod (6) into piston (4), secure by nut (10) and
introduce into cylinder (5). Place spring (3) in piston
(4). Fit cover (1) with new 0-seal (2). Fit screws (8)
with lockwashers (9). Check that piston (4) moves
freely by introducing rod (6).
Refitting the on/off control
Clean joint faces of on/off control ram, shim pack
and bracket. Place shim pack on bracket. Position
ram and secure by bolts (16). Introduce end fitting
(18) into rod (6) and drive in dowel sleeve (7). Con-
nect air piping.
Check governing linkage setting (Job Card
05.04.04).
JC 05 - Page 56 0299 6476-0125 © 0301

Governor
05.09.01
Starting pressure booster servicing/reconditioning
Tools
- Standard tools
Cross-references
- Job Card 05.00.01, 05.03.01, 05.03.02
Servicing
Remove, dismantle and service/recondition booster,
especially when during the starting cycle there has
been oil or excessive air emission through breather
ports (16).
Note
As the engine is started, the booster is pressurized
by air. The governor oil present in the booster is
pressed by piston (6) through check valve (20) into
the hydraulic governor which thus becomes opera-
tive.
Job
Dismantling the booster
Disconnect oil lines (21) and (22) plus air line Fig. 1 Check valves (83311_0)
Detach booster from auxiliary drive. Screw out
check valves (20) and (23). On unscrewing bolts (3)
(Caution: spring is under pressure!), remove cover
(2) and gasket (4) from housing (7). Take spring (17)
out of piston (16). Turn housing (7) upside down.
Unscrew bolts (1) and remove cover (12) with gas-
ket (9). Push piston (6) out of housing (7).
Clean all components and inspect for wear. If the
piston running surfaces in housing (7) are scored,
polish them by compound. Then clean housing (7).
Replace 0-seal (5). (For replacing V-seals (15) and
(18) see RECONDITIONING overleaf.)
© 0301 0299 6476-0125 JC 05 - Page 57

Governor
05.09.01
Fig. 2 Booster (83312_0)

Reassembling the booster Reconditioning
Slightly apply oil to all components. Introduce piston (Replacing V-seals)
(6) into housing (7). Fit cover (12) with new gasket
Unscrew bolts (13) for replacing V-seal (14).
(9). Turn housing (7) upside down, install spring (17)
Remove spring cap (8) with gasket (14). When fit-
and mount cover (2) with new gasket (4).
ting the new V-seal, check that it is correctly seated.
Assemble check valves (20) and (23) and mount to Install spring cap (8) with new gasket (14).
booster. Attach booster to auxiliary drive. Connect
Unscrew bolts (1) and remove washer (19) for repla-
oil pipes (21) and (22) in the correct direction of flow
cing V-seal (18). When installing the new V-seal,
and bleed air pipe (10).
check that it is correctly seated. Finally fit bolts (1)
Check governor setting (Job Card 05.03.02). with washer (19).
Top up governor oil (Job Card 05.03.01).
JC 05 - Page 58 0299 6476-0125 © 0301

Exhaust gas system/Charging
06.01.01
Exhaust manifold inspection/reconditioning, 6-cyl.
Inspecting Tools
When servicing the cylinder head (Job Card - Standard tools
01.08.01), inspect degree of soiling inside the mani-
fold. When heavy built-ups of soot are found, - Cranked box wrench
remove manifold for cleaning. - Socket-head wrench
Aids
- DEUTZ S1 compound
Cross-references
- Job Card 01.08.01
Job Reconditioning
Remove external manifold guard (lagging). Inspect Removing/refitting manifold
manifold and heat insulation. Also, inspect manifold Remove guard an all interfering piping as well as
for freedom from leaks. Such leaks through cracks joint insulating mats (4). Then disconnect manifold
or slackened bolts are usually indicated by soot section with retainers and expansion joints, prefe-
deposits at these points. Check tighhness of all bolts rably starting from the turbocharger far side.
(1) securing manifold sections to cylinder heads.
Fig. 1 Exhaust manifold (50005_0)
© 0301 0299 6477-0125 JC 06 - Page 1

06.01.01
Clean manifold sections and bellows-type expan-

sion joints P inside and make sure that joints and
protective tube are not defective.
Refitment is made in the reverse order to removal.
Caution!
Before fitment of expansion joints check
that indivual manifold branches are aligned,
so joints can be installed free from internal
stressing. Note gas flow as arrowed on
joint.
Note
Apply DEUTZ S1 compound to all thermally stres-
sed boltings and gaskets. To do this, thoroughly
remove all traces of dirt and apply a thin coat (10 -
12 µm thickness of dry film) of compound by hair
brush or preferably by spraying appliance.

Ex Exhaust gas flow
N Over-all length
Max Max. installation length
JC 06 - Page 2 0299 6477-0125 © 0301

06.01.01
Inspecting Tools
Aids
- DEUTZ S1 compound
Cross-references
- Job Card 01.08.01
Job Reconditioning
(2) securing manifold sections to cylinder heads.
© 0301 0299 6477-0125 JC 06 - Page 3

06.01.01

Caution!
Before fitment of expansion joints check
that indivual manifold branches are aligned,
so joints can be installed free from internal
stressing. Note gas flow as arrowed on
joint.
Note
remove all traces of dirt and apply a thin coat (10-

Ex Exhaust gas flow
N Over-all length
JC 06 - Page 4 0299 6477-0125 © 0301

06.01.01
Inspecting Tools
Aids
- DEUTZ S1 compound
Cross-references
- Job Card 01.08.01
Job Reconditioning
securing manifold sections to cylinder heads.
For example, on the left-hand engine side (A-side)
remove components in the order (1) to (18).
Fig. 1 Exhaust manifold, A-side (83445_0)
© 0301 0299 6477-0125 JC 06 - Page 5

06.01.01
Fig. 2 Exhaust manifold, B-side (83446_0)

Caution!
Be sure all exhaust elbows are in line, so
expansion joint can be installed free from
internal stressing. See arrow on joint flange
for correct direction of gas flow.
Note

Ex Exhaust gas flow
N Over-all length
JC 06 - Page 6 0299 6477-0125 © 0301

06.01.01
Inspecting Tools
Aids
- DEUTZ S1 compound
Cross-references
- Job Card 01.08.01
Job Reconditioning
securing manifold sections to cylinder heads.
For example, on the right-hand engine side (B-side)
remove components in the order (1) to (31).
Fig. 1 Exhaust manifold, A-side (83448_0)
© 0301 0299 6477-0125 JC 06 - Page 7

06.01.01
Fig. 2 Exhaust manifold, B-side (83449_0)

Caution!
Be sure all exhaust elbows are in line, so
expansion joint can be installed free from
internal stressing. See arrow on joint flange
for correct direction of gas flow.
Note

Ex Exhaust gas flow
N Over-all length
JC 06 - Page 8 0299 6477-0125 © 0301

06.02.01
Charge air system inspection, In-line engine
Inspection Tools
When servicing a piston, inspect charge air pipe - Standard tools
inside and clean as necessary.
Aids
- DEUTZ F5 compound
- DEUTZ S1 compound
Note
During engine service, open drain valve several
times a day. If water comes out each time, inspect
the associated charge air cooler (2) for leaks.
Caution!
Large amounts of condensate may also be
due to the dew point not being attained
because of low charge air temperature. In
this case reduce engine power and raise
charge air temperature to the specified level
(see Technical Data).
Job
Remove cover (4). Inspect air pipe inside and clean
as required. Refit cover (4) with new 0-seal (6).
Check that bolts securing pipes to brackets of
charge cooler (2) and bolts securing branches (3) to
cylinder heads are tight.
While the engine is running, also check adapters (5) Fig. 1 Charge air system (83316_0)
for tightness. Should air leak out, replace 0-seals (8)
and (11).
© 0301 0299 6477-0125 JC 06 - Page 9

06.02.01
Fig. 2 Charge air system (83315_0) Note

Tighten the middle clip so that it can just no longer Apply DEUTZ S1 to all thermally stressed boltings.
be turned on the rubber sleeve (1). To do this, thoroughly remove all traces of dirt and
Determine dimension “a”. Shorten tube (22) to apply a thin coat of compound by hair brush or pre-
dimension “a”, and install. ferably by spraying appliance.
The clamping cheeks of adjacent clips are to be fit-
ted at a displacement to each other of 90°. Replace
any leaky sleeves.
Fig. 3 Charge air system (50030_0) Fig. 4 Charge air system (83317_0)
Reconditioning
Replacing 0-seals of an adapter
Stop engine.
If an adapter (5) has become leaky, unscrew bolts
(9) and remove clips (10). With the aid of two
screwdrivers, push adapter (5) sideways into branch
(3) so 0-seal (11) can be removed. Apply DEUTZ F5
compound to new 0-seal and install. Push adapter
to the other side and replace 0-seal (8) similarly.
Finally push adapter back to its central position and
fit clips (10) plus bolts (9).
JC 06 - Page 10 0299 6477-0125 © 0301

06.02.01
Charge air system inspection, 12-cyl.
Inspection Tools
Aids
- DEUTZ F5 compound
- DEUTZ S1 compound
Note Job
During engine service, open drain valve several Remove cover (5). Inspect air pipe inside and clean
times a day. If water comes out each time, inspect as required. Refit cover (5) with new O-seal.
the associated charge air cooler (2) for leaks. Check that bolts securing pipes to brackets of
Caution! charge cooler (2) and bolts securing branches (3) to
Large amounts of condensate may also be cylinder heads are tight.
due to the dew point not being attained While the engine is running, also check adapters (4)
because of low charge air temperature. In for tightness. Should air leak out, replace O-seals
this case reduce engine power and raise (10) and (13).
charge air temperature to the specified
level (see Technical Data).
Fig. 1 Charge air system (83451_0)
© 0301 0299 6477-0125 JC 06 - Page 11

06.02.01
Tighten the middle clip so that it can just no longer

be turned on the rubber sleeve (1).
Determine dimension “a”. Shorten tube (22) to
dimension “a”, and install. The clamping cheeks of
adjacent clips are to be fitted at a displacement to
each other of 90°.
Replace any leaky sleeves.

Reconditioning
Stop engine.
(3) so O-seal (10) can be removed. Apply DEUTZ
F5 compound to new O-seal and install. Push adap-
ter to the other side and replace O-seal (13) simi-
larly. Finally push adapter back to its central
position, and fit clips (11) plus bolts (12).
Note
Apply DEUTZ S1 to all thermally stressed boltings.
To do this, thoroughly remove all traces of dirt and
apply a thin coat of compound by hair brush or pre-
ferably by spraying appliance.
JC 06 - Page 12 0299 6477-0125 © 0301

06.02.01
Charge air system inspection, 16-cyl.
Inspection Tools
Aids
- DEUTZ F5 compound
- DEUTZ S1 compound
Note Job
During engine service, open drain valve several Remove cover (1). Inspect air pipe inside and clean
times a day. If water comes out each time, inspect as required. Refit cover (1) with new O-seal.
the associated charge air cooler (4) for leaks. Check that bolts securing pipes to brackets of
Caution! charge cooler (4) and bolts securing branches (2) to
Large amounts of condensate may also be cylinder heads are tight.
due to the dew point not being attained While the engine is running, also check adapters (3)
because of low charge air temperature. In for tightness. Should air leak out, replace O-seals
this case reduce engine power and raise (10) and (13).
charge air temperature to the specified level .
(see Technical Data).
© 0301 0299 6477-0125 JC 06 - Page 13

06.02.01
Tighten the middle clip so that it can just no longer

be turned on the rubber sleeve (1).
Determine dimension “a”. Shorten tube (22) to
dimension “a”, and install. The clamping cheeks of
adjacent clips are to be fitted at a displacement to
each other of 90°.
Replace any leaky sleeves.

Reconditioning
Stop engine.
(2) so O-seal (10) can be removed. Apply DEUTZ
F5 compound to new O-seal and install. Push adap-
ter to the other side and replace O-seal (13) simi-
larly. Finally push adapter back to its central
position, and fit clips (11) plus bolts (12).
Note
Apply DEUTZ S1 to all thermally stressed boltings.
To do this, thoroughly remove all traces of dirt and
apply a thin coat of compound by hair brush or pre-
ferably by spraying appliance.
JC 06 - Page 14 0299 6477-0125 © 0301

06.03.11
Intake air cleaner (Plastics) servicing
Servicing Tools
This job card refers only to “Fibroid-elastov 30” filte- - Standard tools
ring mats produced by Delbag.
The cleaner consists of four or six segments. If Aids
removal of a filtering mat from one of the segments
during engine service causes the air pressure to - Detergent
rise, service entire air cleaner.
Select the cleaning agents to suit the type of soiling

involved:
- e.g. a cleaning solution with a mixture compri-
sing 20 l of water and 200 g of P 3 - T 308
(Messrs. Henkel). Temperature of the cleaning
solution approx. 50 °C,
- or a cleaning solution from another company, in
an equivalent quality.
Note
It is recommendable always to keep one set of mats
in reserve, enabling it to be cleaned while the
engine is running.
Job
Stop engine. Open clips (1) of one segment and
remove one mat (2). Put mat in a vessel filled with
detergent and let soak for a few minutes. Wash mat
and rinse in fresh water. Let mat drip off and dry.
Reinstall mat (2) and tighten clips (1).
Never squeeze or fold mats!
Note
Use can also be made of expendable plastics-type
Freudenberg Viledon PSB 1290 filter mats, which
are temperature-resistant up to approx. 70 °C.
Being only of 15 mm thickness, two layers of mats
must be installed in one segment. Fig. 1 Turbocharger (83318_0)
© 0301 0299 6477-0125 JC 06 - Page 15

06.03.11
JC 06 - Page 16 0299 6477-0125 © 0301

06.04.01
Charge air cooler (twin-circuit), water side servicing
Servicing Tools
Remove charge air cooler. Inspect and, if neces- - Standard tools
sary, remove nest of tubes for cleaning the water
side. - Hoist
- Cylindrical plastics brush
Note
Water side cleaning is due when the charge tempe-
rature measured after cooler exceeds the limit spe-
cified in the acceptance test sheet.
Fig. 1 Charge air cooler (83319_0)

Removing the cooler
Close shut-off valves in water inlet and outlet piping.
Caution!
Drain all water from cooler. Unscrew hex. waisted
bolts (1) of air inlet (4) from cooler and remove toge- Do not warp waisted bolts (9).
ther with sleeves (17). Unscrew all hex. bolts (3) at Removing end covers (10) and (11) (see Fig. on
flange (2). Take down air inlet (4). Undo hex. nuts next page)
(6) at base of cooler and remove together with slee-
Unscrew bolts (12). Remove end cover (10) with
ves (17). Disconnect water inlet and outlet piping
gasket (13), and end cover (11) with gasket (14),
from cooler.
from cooler body (15).
Attach cooler to hoist and lift it from its bracket and
waisted bolts (9).
© 0301 0299 6477-0125 JC 06 - Page 17

06.04.01

Mechanical cleaning
When incrustations are not so hard, push plastics 2 1 5
brush through tubing and then flush with a vigorous
jet of water. Be sure, however, not to damage the
natural protective coating formed in service. This
also applies to plastics-coated tubes and tube bot-
toms. Once the plastics coat is damaged, after all,
the nest must be renewed.
Caution!
Never bore out hard incrustations.
Instead, clean tubing by chemical means in
good time.
Clean end covers (10) and (11) and renew gaskets.
Chemical cleaning 3 4
(Detergents: see next page)
Pump a solvent solution through removed cooler
complete with built-on end covers (10) and (11). Items in Fig. 4:
1 Tube bore (1 in.)
2 Pump (4 m3/h)
3 Detergent container (0.5 - 1 m3)
4 Heating (5 kW)
5 Charge air cooler
JC 06 - Page 18 0299 6477-0125 © 0301

06.04.01
The detergent reservoir “B” must be at a higher level Caution!

than the cooler, so that the cooler will not run dry as Never use hydrochloric acid for cleaning!
the pump is stopped. The quantity of energy requi-
red in the form of hot water, steam or electric power Observe safety precautions.
is 5 kW for each 0.5 m3 detergent. Protect your eyes with goggles and your
Chemical Detergents hands with suitable gloves of rubber or pla-
stics, and wear acidresisting clothing!
The detergents used should be pulverized acids on
a sulfamic basis with a heavy proportion of inhibitors After use, neutralize the detergent solution with a
to avoid corrosion of the metal parts. Typical deter- caustic soda solution for environmental protection.
gents are: In addition, let a weak soda solution circulate
through the cooler or stand in the cooler for at least
“Porodox” one hour. It is not permissible to flush the detergent
Messrs. Collardin GmbH with raw water to outboard. Following the chemical
Widdersdorfer Straße 215 cleaning process, remove the nest of tubes to free
the water chambers from any grit, shells, etc. left
D-50825 Cologne behind.
At the same time, examine the tube bottoms and
Concentration 2 - 10 % water chambers for erosion and carry out any
Temperature 20 - 60 °C necessary repairs, using a commercialgrade corro-
sion-resistant two-component compound, e.g. “Bel-
Application max. 16 hours zona” of Molecular Conservation Ltd., Clare Road,
Harrogate/Yorkshire, England. When the compound
Drew´s “SAF-Acid” has hardened, the tube bottom surface should be
levelled. (min. ∇∇ surface quality.)
Messrs. Drew Chemical GmbH
Tube leaks should be remedied by means of a
Börsenbrücke 4 slightly tapering plug of corrosion-resistant material
D-20457 Hamburg such as CuNi or G SnBz. Be sure the specified
charge air temperature is observed, or the engine’s
power will drop.
Concentration 5%
Temperature max. 75 °C
“P3 - T1166”
Messrs. Henkel & Cie GmbH
P.O. Box 1100
D-40002 Düsseldorf
See supplier’s instructions
Neutralizing Agent “P3-croni”

Messrs. Henkel & Cie GmbH
P.O. Box 1100
D-40002 Düsseldorf
See supplier’s instructions
© 0301 0299 6477-0125 JC 06 - Page 19

06.04.01
Refitting the end covers (10) and (11)

Refit end cover (10) with new gasket (13), and end
cover (11) with new gasket (14), using the hex. bolts
(12).
Refitting the cooler
Attach cooler to hoist. Clean joint faces between
cooler body (15) and end covers (10) and (11), and
between bracket (16) and air inlet (4). Fit gasket (8).
Carefully position cooler over waisted bolts (9).
Position sleeves (17) and secure hex. nuts with pre-
loading torque of 78 Nm and final tightening angle of
60°.
Fit gasket (7) and air inlet (4). Insert hex. waisted
bolts (1) with sleeves (17) in cooler body (15), and
tighten with 83 Nm.
Assemble flange (2) with new gasket. Connect
water pipings.
Open shut-off valves, put cooler into operation and
check for leaks.
JC 06 - Page 20 0299 6477-0125 © 0301

06.04.02
Charge air cooler, air side servicing
Tools
- Standard tools
Cross-references
- Job Card 06.04.01
Servicing
When the differential pressure at full load has risen
through 30 %, the cooler air side is due for cleaning.
If necessary, therefore, remove cover (1) following
removal of insulation and inspect degree of cooler
soiling.
Job
Remove nest of tubes (Job Card 06.04.01) and put
into a vessel filled with a detergent solution capable
of softening the cake of dirt. Typical detergents:
ACC9 supplied by DREW Chemical
Vecom B85 supplied by Vecom
P3T-5308 supplied by Henkel, Düsseldorf Fig. 1 Charge air cooler (83321_0)
Strictly observe the supplier’s instructions. The time of softening (soaking) depends on the
extent of soiling. Finally flush tubes thoroughly with
fresh water. Clean corroded baffles, frame, fittings
and finish with a zinc dust paint resistant to some
200 °C.
Reinstall nest of tubes (Job Card 06.04.01) and refit
cooler.
Cleaning by specialists
You have an option for having the air-side cleaning
work performed by an outside company.
© 0301 0299 6477-0125 JC 06 - Page 21

06.04.02
JC 06 - Page 22 0299 6477-0125 © 0301

06.05.01
Turbocharger servicing
Servicing
- Check lube oil level every 100 oper. hrs.
- Initial lube oil change after 100 oper. hrs.
- Periodic lube oil change no later than every 1000
oper hrs.
- Lube oil quality, see Chapter 6 and ABB instruc-
tions
- Lube oil quantity, as well as oil changing proce-
dure in accordance with ABB instructions
Note
When draining lube oil into a tank, apply a hair sieve
- or if not available, use a clean, non-fraying cloth. If
any abraded metal is found in the sieve/cloth, it is
adviseable to clean the lube oil spaces, as well as
bearings in accordance with ABB instructions.
© 0301 0299 6477-0125 JC 06 - Page 23

06.05.01
JC 06 - Page 24 0299 6477-0125 © 0301

06.06.01
Turbocharger servicing/reconditioning
Cross-references
- Job Card 05.00.01
Servicing and reconditioning

- Observe safety precautions (Job Card 05.00.01).
- Carry out work according to ABB instructions or
have carried out by ABB Service.
- Outlet temperature of coolant (s. Chapter 3.3.2).
© 0301 0299 6477-0125 JC 06 - Page 25

06.06.01
JC 06 - Page 26 0299 6477-0125 © 0301

06.12.01
Turbocharger charger servicing
Aids
- Detergent: clean fresh water
Servicing
Clean the charger unit at full load.
Note
Build-up of dirt deposits and hence loss in power is
prevented by injecting water in service. This is not a
solving but a scavenging process.
Job
Remove cover (2) of cleaning attachment (1) by
turning handle (3) counter-clockwise. Fill housing
(4) with 0.5 litres (VTR 304/354) of fresh water. Refit
cover (2) and close attachment by turning handle (3)
clockwise. Press knob (5) and make sure that the
water is injected from housing (4) within 4 -
10 seconds at maximum engine load (min. 60 %).
Fig. 1 Turbocharger (25434_0)
© 0301 0299 6477-0125 JC 06 - Page 27

06.12.01
Fig. 2 Turbocharger (25435_0)

Note
A success of the cleaning acting is indicated by a
raise of the charge air temperature or a drop of the
exhaust gas temperatures respectively.
Caution!
Wait for min. 10 minutes before repeating
the cleaning operation.
JC 06 - Page 28 0299 6477-0125 © 0301

06.13.01
Turbocharger turbine servicing
Servicing Tools
When the engine is operated on intermediate - Standard tools
(heavy) fuel, clean turbine while in service.
- Hose 1/2”
Aids
- Detergent: clean fresh water
Note
Regular scavenging is designed to prevent the for-
mation of major dirt deposits on the turbine blades.
Soiled turbines cause higher exhaust temperatures
and bearing loads due to imbalances. Therefore,
strictly follow the job description below.
Only V-type engine:
The two turbines of turbochargers fitted on the
engine are to be scavenged one after the other.
Job
1. Reduce your engine’s output until an exhaust
gas temperature before the turbine of 430 °C has
been reached or the mean exhaust gas tempera-
ture after the cylinder is below 350 °C. The char-
ging pressure must be above 0.3 bar and the
turbocharger speed as high as possible.
2. To avoid water collecting in the turbine outlet
housing, fully open drain valve (4) of drain pipe
(5) and make sure that pipe is not blocked
(exhaust gas must pass out). If necessary, push
through with thick wire.
Caution!
Wear gloves against hot exhaust gases.
Fig. 1 Turbocharger, In-line engine (25596_0)
© 0301 0299 6477-0125 JC 06 - Page 29

06.13.01
3. Connect hose to hose fitting (3) of orificie and

pressurize scavenging pipe (2).
4. Slowly open the scavenging nozzles (1).
If no water and/or steam comes out of drain valve
(4) right after starting the water feed, interrupt the
scavenging process immediately and check drain
pipe and valve again for free passage and scaven-
ging nozzles for water feed. Failing this, the water
level will raise in the turbine housing and water will
penetrate into bearing pedestals leading to bearing
damage.
There may be an outflow of 0.1 dm3/min of water
through the drainage valve.
5. Clean turbine for 5 to max. 10 minutes.
6. Close scavenging nozzles (1).
7. Disconnect hose at hose fitting (3) of orifice.
Caution!
Make sure to disconnect hose after every
washing so that no uncontrolled water can
get into the exhaust piping of the engine
outside the washing periods.
8. Close drain valve (4) when no more water or
steam escapes.
9. Gradually raise engine load and continue run-
ning engine under lad for at least 10 minutes to
avoid corrosion damage.
The time between two scavenging operations may
be varied depending on the success of the opera-
Fig. 2 Turbocharger, V-type engine (25602_0) tion.
JC 06 - Page 30 0299 6477-0125 © 0301

06.13.02
Turbocharger scavenging attachment servicing
Servicing Tools
Remove and service water scavenging nozzles (1) - Standard tools
and drain valves (4) (Job Card 06.13.01).
Aids
- DEUTZ S1 lubricating compound
Cross-references
- Job Card 06.13.01
Job
Disconnect water piping from nozzles and drain val-
ves.
Servicing the nozzle
Unscrew nozzle from exhaust manifold (or pulse
converter). Remove hand wheel (1), unscrew hex.
nut (2) and spindle nut (3), take out spindle (5) from
housing (4).
Clean all components, examine for wear and
replace as required. Grind spindle (5) in nozzle and
its top seat in nut (2).
Caution!
Keep wall of nozzle hole (6) intact.
Fig. 1 Nozzle (83322_0)

Renew joint washers and apply DEUTZ S1 to
spindle thread. Reassemble in the reverse order.
Before installing nozzle, apply DEUTZ S1 to thread.
© 0301 0299 6477-0125 JC 06 - Page 31

06.13.02
Servicing the drain valve (6-cyl.)

(Fig. 2)
Unscrew valve from turbocharger housing.
Unscrew spindle nut (12) and take out of housing
(10) along with spindle (11).
Clean all parts.
Grind spindle (11) in housing (10).
Renew joint washers.
Reassemble valve, apply DEUTZ S1 compound to
thread and refit valve in turbocharger housing.
Fig. 2 Drain valve, 6-cyl. (83323_0)

Servicing the drain valve (8-, 12- and 16-cyl.)
(Fig. 3)
Unscrew bolt (13) and remove spindle (14). Turn out
drain valve from turbocharger casing.
Fig. 3 Drain valve, 8-, 12-, 16-cyl. (83455_0)
Unscrew spindle nut (12) and take out of housing
(10) along with spindle (11).
Clean all parts.
Grind spindle (11) in housing (10).
.Renew joint washers.
Reassemble valve, apply DEUTZ S1 compound to
thread and refit valve in turbocharger housing.
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Fuel system
07.01.01
Injection plunger control and locking mechanism, inspection
Inspection Tools
Check that control mechanism moves freely and - Standard tools
that locking mechanism performs satisfactorily.
Note
The injection pump plunger is moved up by the
camshaft through a roller tappet bush (pump drive)
and moved down by a pump spring.
Job
Checking the control mechanism
Easy movement of the governing linkage is essen-
tial for proper performance of the fuel injection
pump. For checking the governing linkage, see Job
Card 05.04.03.
Checking the locking mechanism
With engine running, push in eccentric pin (5)
against spring (6), then turn through 180° to detent
stop.
This will raise the pump drive tappet from cam (8)
and at the same time locate the locking pin
(5).
Caution!
With engine stopped, turn camshaft until the
tappet roller is on top of cam (8). Then press
in pin (5) and turn clockwise throught 180°
to lift the pump drive tappet from cam (8).
For releasing the lock, slowly turn pin (5) anti-clock-
wise through 180° to detent stop.
Tappet bush (7) and pin (5) are thus disengaged
again.
© 0301 0299 6478-0125 JC 07 - Page 1

Fuel system
07.01.01
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Fuel system
07.02.01
Injection pump element, removal/refitting
Tools
- Standard tools
- Puller
- Tube
Cross-references
- Job Card 07.02.04, 07.04.01
Note
Removal of the pump element (1) from body (2) is
necessary, for example, for replacing or servicing
the pump element.
Removing the element
Remove fuel injection pump (Job Card 07.04.01)
from camshaft casing.
Clamp injection pump body (2) in vise. Remove
allen srews (14) from body (2). Take off clamping
plate (14) and screw fitting (16). Withdraw 0-ring
(30) togehter with valve seat (7) from body, using
puller. Remove deflector screws (19) and hex. bolt
(25) from body (2).
Remove spring cap (9) with puller (26) after loading
compression spring (20) (see Fig. 1).
Fig. 1 Pump element (50122_0)
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Fuel system
07.02.01

After undoing the allen screws (29) of flange (6),
while observing the dowel pins (27), pump element
(1) can be withdrawn from body (2).
Refitting the element
Pump element (1) is refitted in reverse order.
Replace O-rings (18) and (30).
Tighten allen screws (15) as per tightening instruc-
tion, so that tube (28) has clearance and will not
seize (see Fig. 4).
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Fuel system
07.02.04
Injection pump-valve seat-sealing, reconditioning
Tools
- Standard tools
- Puller
- Tube
Aids
- Lubricant Parker-O-Lube
Cross-references
- Job Card 07.02.01, 07.04.01
Reconditioning
If an inspection of the injection pump has revealed
an upward leakage of fuel, the leaky O-ring, must be
renewed.
Job
Remove allen screws (15) from body (2) and lift off
clamping plate (14). Pull screw fitting (16) out of
body (2). Take element (17) together with spring
(18) out of valve seat (7). Insert hex. bolts (3) of pul-
ler tool as per fig. below through flange (5) and disc
plate (6), turn into valve seat (7) and tighten. Place
yoke (8) over the bolt of flange (12) and pull valve
seat (7) out of body (2) by turning hex. nut (9).
Clean seats of O-ring in body (2) and valve seat (7)
with diesel fuel.
© 0301 0299 6478-0125 JC 07 - Page 5

Fuel system
07.02.04

Note
Before installing valve seat (7), coat its sealing sec-
tion, housing (2) and O-ring (11) using “Parker-O-
Lube” lubricant.
Insert valve seat (7) into housing (2). Place O-ring
(11) and support ring (10) into housing (2) and press
between valve seat (7) and housing (2) with tube
(27).
Caution!
O-ring must be fitted twist-free.
Use only non-slotted support rings.
Insert element (17) together with spring (18) into
valve seat (7), and place screw fitting (16) in posi-
tion.
Tighten screw fitting (16) together with clamping
plate (14) with allen screws (15) according to Tighte-
ning Specification. Lubricate screw head contact
surface and thread of allen screws (15) before
tightening.
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Fuel system
07.03.01
Injection pump plunger hydraulic seal, checking
Checking Tools
Check pump valve seat sealing. - Standard tools
Note
See engine-specific piping diagrams of sealing oil
system in Chapter 5.
Checking the valve seat seal (1)
In the case of fuel leaking between body (2) and
screw fitting (16) upon switching on the fuel feed
pump, it is necessary to renew the O-ring (1) (Job
Card 02.02.04).
Checking the rubber O-rings (3)
Release banjo bolts of the sealing oil connection (4)
and the drainage bore (5). If sealing oil emerges at
the released drainage connection (5), the rubber O-
rings (3) of the respective pump will be leaky and
must be renewed.
Retighten the banjo bolts and check that all pipe
connections are leak-free.
© 0301 0299 6478-0125 JC 07 - Page 7

Fuel system
07.03.01
JC 07 - Page 8 0299 6478-0125 © 0301

Fuel system
07.03.02
Fuel system, servicing
Tools
- Standard tools
Cross-references
- Job Card 02.00.01
Servicing (bleeding)
Prior to commissioning overhauled or new injection
pumps as well as following fitment of fuel piping, fil-
ter or overflow valve, fill up the entire fuel system
and bleed.
Bleeding the low-pressure system
Open shut-off valve in line running to engine.
Release at first bleeder plugs (2) on fuel filter (3),
then banjo bolt (1) on the distributor.
If necessary, switch on fuel feed pump and prime
system until fuel emerges free from air bubbles at
bleeder plugs (2) and banjo bolt (1). Retighten plugs
and bolt.
© 0301 0299 6478-0125 JC 07 - Page 9

Fuel system
07.03.02
JC 07 - Page 10 0299 6478-0125 © 0301

Fuel system
07.03.04
Pulsation damper, checking, make Hydra
Tools
- Hand-filling appliances
- Coupling
Aids
- Compressed air (min. 5 bar)
Note This check is to be made by means of the handfilling

The fuel, circulating inside the suction chambers of appliances contained in the set of tools via valve
the injection pumps and in the delivery and return connection (2) arranged on the upper section of the
lines, tends to vibrate as a result of the intermittent damper.
supply of fuel to the injection pumps. Therefore, two 1. Determine and write down fuel pressure inside
pulsation dampers (i.e. one in each fuel delivery and supply/return line at full load, as far as possible.
return line) are mounted on in-line and V-type engi- 2. Stop engine, close fuel cocks so that supply lines
nes to reduce these vibrations. The compressed-air are depressurized.
charge of the pulsation damper exerts a dampening
influence upon the transient pressure of the fuel by 3. Determine and write down fuel temperature
means of a diaphragm. The pressure of this air inside supply line.
charge is to be checked at regular intervals and cor- 4. Set filling pressure to be adjusted using fuel
rected, if necessary. pressure and temperature stated in diagram.
Checking and correcting air-charge pressure 5. Unscrew flap (3) and connect hand-filling
Note appliances.
The air-charge pressure inside pulsation damper (1) 6. Check charge pressure and correct, if necessary.
has to be adjusted on the basis of the fuel pressure Should it be observed when checking that the
arising inside the fuel-supply and discharge line at charge pressure has completely or substantially
engine full load as well as the fuel temperature pre- dropped and that the pressure builds up slowly
sent just before checking the pressure. when refilling, the diaphragm has to sure builds up
slowly when refilling, the diaphragm has to be repla-
ced.
© 0301 0299 6478-0125 JC 07 - Page 11

Fuel system
07.03.04
Fig. 1 Illustration (83478_0)

Replacing defective diaphragm 4. Insert pre-assembled upper section of damper
1. Reduce any residual fuel pressure via inner tube into housing and attach with union flange. Tigh-
valve (2). ten screw (4) crosswise up to 20 Nm.
2. Unscrew screws (4), take down union flange (5). 5. Connect hand-filling appliances, filling damper
Lift off upper section (6) of damper using 2 first up to 2 - 3 bar and checking for tightness.
screw-drivers as levers and take it down together 6. Correct charge pressure as per section 1.
with diaphragm (7). Collect flowing-out fuel.
3. Extract diaphragm (7) out of upper section of
damper. Coat bead of new diaphragm slightly
with oil and attach. Take care that bead is pro-
perly seated inside groove.
Fig. 2 Pulsation damper (83327_0)
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Fuel system
07.03.04
Pulsation damper, checking, make Sietas
Aids
- Compressed air (at least 6 bar)
The intermittent fuel delivery from the injec-

tion pumps causes vibrations in the fuel in
the inlet chambers of the injection pumps,
and in the supply and return lines. To com-
bat these vibrations, two pulsation dampers
(one in the fuel supply, the other in the fuel
return line) have been installed. The com-
pressed air content of the pulsation damper
has a damping effect on the pressure fluc-
tuations in the fuel.
The inside of the pulsation damper does not
contain any mechanically moving parts, so
that the pulsation damper requires no
maintenance.
Comply with Instruction (1) from the manu-
facturer. If pressure surges and vibrations
occur in the fuel system, the pulsation dam-
pers must be topped up for 1 – 2 seconds
with clean compressed air (filtered and Fig. 1 Pulsation damper (83530_0)
dewatered) via the compressed air cock.
The compressed air pressure must be
above that of the fuel system.
© 0301 0299 6478-0125 JC 07 - Page 13

Fuel system
07.03.04
JC 07 - Page 14 0299 6478-0125 © 0301

Fuel system
07.03.05
Lube oil filter, servicing
Tools
- Standard tools
Aids
- Detergent
Cross-references
- Job Card 07.03.01
Servicing
Remove, dismantle and clean filter in sealing oil
system and seat lubrication (Section 5.5)
Job
Stop engine.
Close pipe from sealing oil high-level tank. Remove
filter from pipe.
Unscrew bolts (2) and remove strainer (4) from body
(5). Take down gasket (3). Clean strainer (4) outside
in diesel fuel by hair brush. Blow filtered compres-
sed air through element (4) inside out throgh twin
nipple (1). Inspect element for defects. Wash body
(5) in diesel fuel and blow dry.
Put new gasket (3) on body (5). Install element (4)
and secure by bolts (2).
Refit filter in oil line. Open shut-off valve. Check that
all oil connections are tight.
Fig. 1 Lube oil filter (83328_0)
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Fuel system
07.03.05
JC 07 - Page 16 0299 6478-0125 © 0301

Fuel system
07.04.01
Fuel injection pump, removal/refitment
Tools
- Standard tools
- Sealing compound
- Key
- Socket
- Torque wrench
- Setting gauge
Cross-references
- Job Card 07.01.01, 07.03.02, 07.06.01,
07.07.02, 07.04.11
Caution!
Never interchange pipings (1), fuel injection
pumps (2) and shims (3). Mark components
by means of coloured pen or label showing
the cylinder number.
Removing the pump
Shut off fuel feed pipe (4) and sealing oil pipe (5)
upstream of injection pump. Disconnect from pump:
Fuel feed pipe (4), fuel return pipe (6), sealing oil
pipe (5), leak-off fuel pipe (18) and injection pipe (1)
(see Job Card 07.07.02).
Fig. 1 Fuel injection pump (25527_0)
© 0301 0299 6478-0125 JC 07 - Page 17

Fuel system
07.04.01
Fig. 2 Fuel injection pump (25526_0)

Caution!
When all injection pumps shall be removed
it is absolutely necessary to fix before set-
ting gauge, in accordance with job card
07.04.11, to injection pump of cylinder 1
(with R/S/BV12/16M 640: A1/B1) and to
push by hand the injection pump control
between pump body and locking nut.
Read value from control rod indicator and write
down. Then pump may be removed.
Adjust roller (7) of injection pump drive to the base
circle of the injection cam (8).
Undo fastenring screws (9) together with washers
(10) of cover (11) and lift off cover (11) from cams-
haft casing (12). The control mechanism is now free
and can be removed from the control rod. Release
strip (13) from injection pump body. Remove allen
screws (14) and lift out injection pump (2) from
camshaft casing, while paying attention to parallel
pin (15) and roll pins (16) and (17). The shim plates
(3) must remain allocated to the individual cylinders.
JC 07 - Page 18 0299 6478-0125 © 0301

Fuel system
07.04.01
Refitting the pump

Carefully clean joint faces of camshaft casing (12),
injection pump body (2), shim plate (3), cover (11)
and strip (13). Reinstall in the reversed order as for
removal, paying particular attention to the parallel
pin (15) and roll pins (16) and (17). Apply sealing
compound to cover (11) and to strip (13) prior to pla-
cing on camshaft casing (12) and injection pump
body (2) respectively, and bolt up. Tighten allen
screws (14) with key as per instructions.
When using torque wrench 730 V/10 from special
tool kit, set torque Md’ = 95 Nm.
If a different torque wrench is used, the torque is to
be calculated according to the following formula:
engine torque (Md’) = 150 x R / (R+ 0.2) [Nm]
Enter lever lenght R in meter.
A tolerance of +- 5 Nm of the used torque wrench
must not be exceeded.
Securely connect fuel feed pipe (4), fuel return pipe
(6) and sealing oil pipe (5). Loosely connect injec-
tion pipe (1).
Set fuel volume of injection pumps (Job Card Fig. 3 Fuel injection pump (83329_0)
07.06.01).
Check that control rod moves freely (Job Card
07.01.01).
Bleed injection pump (2) (Job Card 07.03.02).
Mount injection pipe (1) as per Job Card 07.07.02.
Check injection timing (Job Card 07.06.01).
© 0301 0299 6478-0125 JC 07 - Page 19

Fuel system
07.04.01
JC 07 - Page 20 0299 6478-0125 © 0301

Fuel system
07.04.02
Injection locking device, removal/refitment
Tools
- Standard tools
Cross-references
- Job Card 07.04.01
Removing the locking device

Remove allen screws (11) together with spring lock-
washers. Pull out locking device (15) from camshaft
casing (16). Take off gasket (10).
Refitting the locking device
Insert locking device (15) together with intakt gasket
(10) into camshaft casing (16). Refit allen screws
(11) together with spring lockwashers.
Fig. 1 Locking device (25521_0)
© 0301 0299 6478-0125 JC 07 - Page 21

Fuel system
07.04.02
JC 07 - Page 22 0299 6478-0125 © 0301

Fuel system
07.04.03
Injection pump drive, reconditioning
Drive overhaul is required in particular when the rol- - Standard tools
ler is defective or the tappet bush is binding.
- Puller
Cross-references
- Job Card 07.04.01, 07.04.02
Removing the drive

Remove injection pump (Job Card 07.04.01), as
well as the locking device (Job Card 07.04.02).
Using puller (15), withdraw complete pump drive
from camshaft casing (14). Take roller tappet bush
(3) and tappet quide (11) out of bush (12). Drive
dowel sleeve (6) into pin. Press roller pivot pin (5)
out of roller tappet bush (3) and take off roller (4)
together with bush.
Clean all parts in diesel fuel. Blow out oil hole of rol-
ler pivot pin (5) with compressed air. Inspect all
parts for wear and renew as required. Renew 0-seal
(10).
Reassembling the drive
Apply light film of oil to all components. Install roller
(4) and pivot pin (5) with bore ø4 facing downwards
and ø5 upwards in roller tappet bush (3) and secure
by means of dowel sleeve (6).
© 0301 0299 6478-0125 JC 07 - Page 23

Fuel system
07.04.03

Refitting the drive
Install bush (12) in camshaft casing, while noting
location of parallel pin (13). Insert pump drive in
bush (12), paying attention to tappet guide (11) and
making sure that the bush hole coincides with the
seat hole for the locking device in the camshaft
casing.
Reinstall locking device (Job Card 07.04.02) and
refit injection pump (Job Card 07.04.01).
JC 07 - Page 24 0299 6478-0125 © 0301

Fuel system
07.04.11
Fuel injection pump and connecting linkage, mounting
Tools
- Standard tools
- at least 2 setting gauges
Cross-references
- Job Card 07.04.01
Note
If one or several fuel injeciton pumps had been
removed the connecting linkage is mounted for refit-
ting of pump(s).
Job
If individual injection pumps are to be refitted, pro-
ceed as follows:
Loosen clamping screws (1) of the pumps to be
refitted. Fit one setting gauge (2) to the pump left in
the camshaft casing; fix further setting gauges - as
illustrated at right - on the injection pumps to be
installed.
Press injection pump control rods by hand against
fuel stop so that the setting gauges are clamped
between pump body and locking nut. Make sure that
setting gauges (2) are positioned properly.
Lock control rod in place.
Tighten clamping screws (1) between levers (3) and
control rods and seal with paint. Fig. 1 Injection pump - connecting linkage (83330_0)
Make sure that position of levers (3) is not changed
when tightening the clamping screws (1).
Remove all setting gauges (2) from the injection
pump control rods before setting the engine into
operation.
Check connecting linkage for proper functioning
(mobility of injection pump control rods).
© 0301 0299 6478-0125 JC 07 - Page 25

Fuel system
07.04.11
Fig. 2 Injection pump - connecting linkage (83331_0)

If all injection pumps shall be refitted without one
injeciton pump being left in the camshaft casing,
proceed as follows:
Fit injection pump to cylinder 1 (with R/S/BV12/16M
640: A1/B1) according to Job Card 07.04.01
Fasten setting gauge (2) to this pump and press
injection pump control rod by hand againt fuel stop
so that setting gauge is clamped between pump
body and locking nut.
Turn connecting linkage until fuel charge indicator
shows again the value recorded before removal of
the injection pump (see Job Card 07.04.01).
Tighten clamping screw (1) and seal with paint.
Remaining jobs to be performed as described under
installation of individual injection pumps.
JC 07 - Page 26 0299 6478-0125 © 0301

Fuel system
07.06.01
Geometrical commencement of delivery, setting and checking
Cross-references
- Job Card 04.06.01, 04.06.02
Setting During the measurement the injection pump drives

Setting of geometrical commencement of delivery must rest on the base circle of the respective injec-
(COD) requires correct basic setting of the camshaft tion cams.
relative to the crankshaft (see Job Card 04.06.02). Checking
The DOD is set by inserting shims between injection If the geometrical COD is to be checked, proceed
pump suport and camshaft casing. The exact values according to Job Card 04.06.02..
are given in the acceptance test record. If they are
missing, value “X” should be taken from the table
below.
Rated speed rpm α Basic setting of X Depth measure Idle stroke +-0.1 Actual geometrical
(1/min) camshaft w.6mm with inserting shims (mm) COD
upmost position +- 0.1 (mm) +- 0.5 (°Cs)
+- 0.2 (°Cs)
631 - 650 24.5 137.0 6.0 24.5
601 - 630 24.5 137.0 6.0 24.5

571 - 600 25.0 137.0 6.0 25.0
541 - 570 25.5 137.0 6.0 25.5
© 0301 0299 6478-0125 JC 07 - Page 27

Fuel system
07.06.01
JC 07 - Page 28 0299 6478-0125 © 0301

Fuel system
07.07.01
Injector removal/refitment
Tools
- Standard tools
- Removing device
Aids
- DEUTZ S1 compound
Cross-references
- Job Card 07.03.02, 07.07.02, 01.11.01,
01.11.02
Removing the injector

Stop engine. Open indicator valves. Switch off
nozzle coolant pump. Disconnect fuel injection pipe
(4), (Job Card 07.07.02) and backleakge pipe (2).
Remove rocker chamber cover.
Unscrew nut (6) and remove yoke (8). Fit removing
device as follows: screw puller spindle (17) into
injector adjusting screw (3) as far as it will go. Fit
tube (16), cross bearer (15), washer (14) and nut
(13). Check that tube (16) is squarely seated on
cylinder head (18). Retain puller spindle at its
square part (12) and withdraw injector (5) from head
by screwing in nut (13). Remove washer (10) bet-
ween injector and its seat in head. Thoroughly clean
sleeve (11) and seating. Blank off injector receiving
bore in head.
Fig. 1 Injector (83332_0)
© 0301 0299 6478-0125 JC 07 - Page 29

Fuel system
07.07.01

Refitting the injector
Fit new washer (10). Slightly apply DEUTZ S1 com-
pound to nozzle and injector seating. Install injector
(5). Fit yoke (8) and domed washer (7). Screw nut
(6) loosely in place. Connect coolant pipe (1) and
backleakage pipe (2), using new washers (19) and
(20). Loosely attach injection pipe (4) (Job Card
07.07.02). Tighten nut (6) as per tightening instruc-
tions.
JC 07 - Page 30 0299 6478-0125 © 0301

Fuel system
07.07.02
Injection pipe dismounting/mounting
Tools
- Standard tools
- Single open-end wrench
Cross-references
- Job Card 07.03.02, 07.04.01, 07.07.01,
07.07.03
Dismounting injection pipe (1) at injector and/or Note

injection pipe (2) at injection pump If the inside diameter of the injection pipe end has
Stop engine decreased to below 3 mm, the pipe must be rene-
When loosening the union nuts (4), the counterpart wed (see Job Card 07.07.03).
mus be held securely by wrench (important with
regard to inlet adapter of injector).
Fig. 1 Injection pipe (25263_0)
© 0301 0299 6478-0125 JC 07 - Page 31

Fuel system
07.07.02
Mounting injection pipe (1) at injector and/or in-

jection pipe (2) at injection pump
Caution!
Before mounting the injeciton pipes, it is
essential to loosen the retainer (3) with
regard to mounting injection pipe (1), and
also the yoke (10) for the injector. Check
whether the clamping sleeves are screwed
on tightly up to end of thread of inlet adap-
ter of injection pipes.
The injection pipes, counterparts and connecting
parts must be checked for cleanliness, free pas-
sage, and condition. If necessary, renew 0-seals (6)
and (7).
Introduce injection pipes at both ends into the
sealing cones. In the case of injection pipe (1),
check also that soldered-on pipe is in direction of
retainer (3).
Beginning at the injection pump, push the relevant
pipe ends into the sealing cones and screw on the
union nuts by hand.
If it is not possible to screw on the union nuts by
hand, find out the cause and rectify accordingly.

Tighten the union nuts hand-tight.
Securely tighten retainer (3) and yoke (10). Tighten
hex. nut (11) as per instructions.
Securely tighten union nut (4) as per instructions.
Mount connection for fuel backleakage pipe.
Upon restarting the engine, check for leaks.
JC 07 - Page 32 0299 6478-0125 © 0301

Fuel system
07.07.03
Injection pipe reconditioning
Tools
- Standard tools
- Spigot wrench
Cross-references
- Job Card 07.07.02
Reconditioning
If the inside diameter of the injection pipe end has
decreased to below 3 mm owing to frequent assem-
bly or a no-permissible degree of tightening, the
pipe must be renewed.
Job
Disconnect injection pipe as per Job Card 07.07.02.
Usin spignot wrench (12), screw off the clamping
sleeves (5) at both ends of the pipe.
Caution!
Left-hand thread
Remove both unio nuts (4) from pipe and renew 0-
seals (6) and (7) in the union nuts.

Caution!
Before fitting the injection pipe, screw on
clamping sleeves (5) up to end of thread
and check tightness with spigot wrench
(12). Note left-hand thread.
Equip new injection pipe with the union parts in
reversed order, and fit as per Job Card 07.07.02.
© 0301 0299 6478-0125 JC 07 - Page 33

Fuel system
07.07.03
JC 07 - Page 34 0299 6478-0125 © 0301

Fuel system
07.08.01
Injector inspection/testing
Tools
- Standard tools
- Testing outfit
- Nozzle cleaner
Cross-references
- Job Card 07.07.01, 07.09.01
Inspection/testing Caution!
Apart from the periods specified in the Maintenance Keep your hands away from the fuel jet!
Schedule (Summarized Operating Instructions), When it penetrates the skin tissue, blood
injectors must be inspected and tested whenever poisoning may be the result.
they fail to work properly. Checking the nozzle for tightness
Injectors not in good working order are indicated by Operate hand lever until the gauge reads 35 bar
changes in normal exhaust colour and tempera- less than the specified pressure. Check that there
tures, which may be due to blocked nozzle holes, will be no afterdribble within 10 seconds.
binding nozzle needle or leaky needle seat. Follo-
wing removal (or overhaul) of injectors, check these
for correct release pressure, tightness, jet pattern
and free flow through cooling passage (where appli-
cable). We recommend having the injectors tested
for higher flow value by a specialized service shop.
Note
Use for test fuel only clean gas oil. (Pressure see
Acceptance Certificate.)
Job
Clean injector (4) outside and free all nozzle orifices
with the tool provided. Install injector in testing outfit,
clamp down by wing screws and connect injection
line to adapter (3). Operate hand lever (6) vigo-
rously for a few strokes.
Checking the injection release pressure
Cut in gauge (5). Force down hand lever (6) slowly
until the nozzle opens. If the pressure reading at this
moment departs from the specified pressure,
release hex. nuts (2), adjust pressure with adjusting
screw (1) and resecure nut. Fig. 1 Injector (83334_0)
© 0301 0299 6478-0125 JC 07 - Page 35

Fuel system
07.08.01
Buzzing and atomizing tests

Operate hand lever quickly (one or two downstrokes
per second) and check that the nozzle emits a buz-
zing sound. Observe nozzle jet pattern. The fuel
must emerge uniformly from all nozzle holes. In the
case of cooled injectors, check that cooling chan-
nels are free.
If any one of the tests is not satisfactory, recondition
injector (Job Card 07.09.01).
JC 07 - Page 36 0299 6478-0125 © 0301

Fuel system
07.09.01
Injector reconditioning
Tools
- Standard tools
- Nozzle cleaner
Aids
- DEUTZ S1 compound
- DEUTZ S2 compound
- DEUTZ F5 compound
Cross-references
- Job Card 07.08.01
Reconditioning Caution!
Injectors which have been tested and approved for To prevent corrosion, be sure to keep your
flow value by a specialized service shop may be re- fingers away from the lapped faces of holder
used. If not approved, they have to be renewed. (5), nozzle (9) and needle (8) once cleaning
Non-tested injectors which have attained the num- is finished.
ber of service hours stated in the Maintenance
Schedule should be given new nozzles.
Note
Exercise utmost cleanliness when re conditioning
an injector. Use no metallic tools for cleaning.
The job should prferably be entrusted to a speciali-
zed workshop.
Removing the nozzle
Loosen nut (1) and turn adjusting screw (3) until
spring (4) is unloaded. Clamp down nozzle holder
(5) at its square top in a vise. Remove carbon sur-
face of nozzle (9) and washer (11). Release nozzle
nut (7).
Release nut (7) with nozzle (9) consistently contac-
ting the flat surface of nozzle holder (5), otherwise
dowel pins (10) are liable to be sheared off.
Take down nozzle (9) with needle (8) from holder
(5). Clean all components in diesel fuel. Clean coo-
lant passages in holder (5) and nozzle (9).
© 0301 0299 6478-0125 JC 07 - Page 37

Fuel system
07.09.01
Introduce needle (8) with diesel fuel into nozzle (9). Dismantling the injector as a whole
Pulled out half at its thrust pin, the needle must sink Release nut (1) and remove adjusting screw (3).
back onto its seat by its own weight. Should the Turn holder (5) upside down to take out spring (4)
needle bind, it must be replaced as a unit with the and plunger (6). Remove nozzle as described
nozzle. Never remachine a nozzle. before. Clean all components. Renew 0-seal (2).
Caution! Reassembling the injector as a whole
Since new nozzles are supplied in greased Introduce plunger (6) and spring (4) into cleaned
condition, clean them in diesel fuel before nozzle holder. Turn in adjusting screw (3) through a
fitment. few threads. For installation of nozzle and setting of
injector see above.
Note
Be sure to tighten a new or overhauled inlet adapter
(12) as specified in the tightening instructions.
Fig. 2 Nozzle (83336_0)

Refitting the nozzle
Clamp down holder (5) in a vise with flat face at top.
If dowel pins (10) present shear marks, replace
pins. Place nozzle (9) and needle (8) on the care-
fully cleaned and dried flat surface. Apply DEUTZ
S2 compound to thread of nut (7) and pressure face
between holder (9) and nut (7). Screw nut in place
and tighten through 250 Nm.
Set injector by testing outfit (Job Card 07.08.01) and
check setting. Apply S1 compound to injector, so it
cannot seize in the cylinder head. Install injector in
head (Job Card 07.07.01).
JC 07 - Page 38 0299 6478-0125 © 0301

Fuel system
07.10.01
Fuel duplex filter servicing (unheated)
Servicing Tools
Clean the filter. - Standard tools
- Brush
Aids
- Diesel fuel
Note
Normally, during engine operating, fuel flows
through only one chamber of the 2-stage filter. If the
differential pressure is exceeded, that is, if the diffe-
rential pressure indicator is red over the entire field,
the reserve chamber must be switched on. This
cause the differential pressure to drop immediately.
Clean the contaminated filter chamber at once.
Removing the filter element
Open bleeder (3) of the dirty chamber through a few
turns. Unscrew plug (12) and drain sludge. Remove
bleeder (3) together with locking plate (13). Uns-
crew nuts (2) and remove cover (4). Unscrew hex.
nut (6) and take out strainer pack (10).
Cleaning the filter
Remove sludge from body bottom and flush body
(11) with diesel fuel. Pull out inner ring (7) from
outer ring (8) and likewise clean in diesel fuel.
Remove sticky dirt with a hair brush. Blow through
Fig. 1 Fuel duplex filter (83337_0)
strainer inside out with an air blast and inspect for
defects. Renew 0-seal (9). Reassemble rings (7)
and (8).
© 0301 0299 6478-0125 JC 07 - Page 39

Fuel system
07.10.01
Refitting the filter element

Install cleaned strainer pack (10) in body (11).Fit
self-locking nut (6) and tighten securely. Fit cover
(4) with a new gasket (5). Tighten cover nuts (2)
evenly crosswise. Close drain valve (12). Refit blee-
der (3) with locking plate (13). For bleeding the clea-
ned filter chamber, place change-over cock (1) in
central position, so both chambers are in service.
Open bleeder (3) through a few turns and keep
open until fuel emerges free from air bubbles. Close
bleeder (3). Move changeover lever (1) so that the
cleaned filter chamber is kept in reserve.
JC 07 - Page 40 0299 6478-0125 © 0301

Fuel system
07.10.01
Fuel duplex filter servicing (heated)
Servicing Tools
Clean the filter. - Standard tools
- Brush
Aids
- Diesel fuel
Note
Normally, during engine operation, fuel flows
through only one chamber of the 2-stage filter. If the
differential pressure is exceeded, that is, if the diffe-
rential pressure indicator is red over the entire field,
the reserve chamber must be switched on. This
causes the differential pressure to drop immediately.
Clean the contaminated filter chamber at once.
Removing the filter element
Open bleeder (3) of the dirty chamber through a few
turns. Unscrew plug (12) and drain sludge. Remove
bleeder (3) together with locking plate (13). Uns-
crew nuts (2) and remove cover (4). Unscrew hex
nut (6) and take out strainer pack (10).
Cleaning the filter
Remove sludge from body bottom and flush body
(11) with diesel fuel. Pull out inner ring (7) from outer
ring (8) and likewise clean in diesel fuel. Remove
sticky dirt with a hair brush. Blow through strainer
inside out with an air blast and inspect for defects.
Renew 0-seal (9). Reassemble rings (7) and (8).
Fig. 1 Fuel duplex filter (83338_0)
© 0301 0299 6478-0125 JC 07 - Page 41

Fuel system
07.10.01
Refitting the filter element

Install cleaned strainer pack (10) in body (11). Fit
self-locking nut (6) and tighten securely. Fit cover
(4) with a new gasket (5). Tighten cover nuts (2)
evently crosswise. Close drain valve (12). Refit
bleeder (3) with locking plate (13). For bleeding the
cleaned filter chamber, place change-over cock (1)
in central position, so both chambers are in service.
Open bleeder (3) through a few turns and keep
open until fuel emerges free from air bubbles. Close
bleeder (3). Move changeover lever (1) so that the
cleaned filter chamber is kept in reserve.
JC 07 - Page 42 0299 6478-0125 © 0301

Lube oil system
08.01.01
Lube oil sampling
Inspection Tools
Regular inspection of the lube oil is essential for - 1 litre container (sheet metal or plastics)
determining the engine’s working condition.
Note Note
With the engine running, oil samples should prefe- The analysis results should be taken as a basis for
rably be taken by the same man at some 60 °C oil arranging with the oil suppliers a regular oil change
temperature. period, taking also into consideration the cleanliness
Job of the lube oil system, especially that of the engine’s
crankcase. Once the interior is coated with the oil
Draw oil from a line before the filter or from the feed residues, this invariably calls for renewal of the
line to the separator and pour away into the dirty oil entire oil filling.
tank, so any impurities at the sampling point will be
removed. Then drain about 1 litre into a clean con-
tainer and send this in completely sealed condition
to a laboratory with a tag or label giving the following
information:
- Engine model and serial No., rated power and
speed, see maker’s nameplate
- Total engine running hours
- Engine application
- Oil bran and grade
- Oil viscosity
- Total oil service hours and refill quantity during
this period
- Fuel used
Along with this sample of used oil, send in a sample
of the oil in fresh condition.
© 0301 0299 6479-0125 JC 08 - Page 1

Lube oil system
08.01.01
JC 08 - Page 2 0299 6479-0125 © 0301

Lube oil system
08.02.01
Lube oil system inspection
Inspection Tools
Carry out inspection and servicing work on the lube - Standard tools
oil system.
Cross-references
- Job Card 08.09.02
Note Caution!
Unsuitable lube oil may cause sticking of piston Have a look at the differential pressure
rings, seizure of pistons, hot running of bearings gauge on the oil filter every 30 minutes
and increased wear and tear of the entire engine. during the initial 24 running hours of a
Be sure, therefore, to use a lube oil meeting the newly commissioned engine. As the red
minimum quality requirements specified (For lube oil alarm sector appears, change over to the
quality and lube oil viscosity, see Chapter 6 Expen- standby chamber, which will reduce the
dables). pressure immediately.
Job Clean soiled chamber (Job Card 08.09.02).
Make a point of regularly observing oil pressures
and temperatures in service and recording the rea-
dings every day.
Check the following oil levles:
- engine oil sump
- turbocharger
- hydraulic governor
Carry out the following additional work:
- Make sure that all pipe unions and connections
are tight.
- At larger intervals, lubrecate by hand all bearings
not connected to the main lube circuit or to the
lubricator. This in particular applies to the
governor/injection pump linkage joints.
- During the running-in program following overhaul
work, check all accesible bearings for correct
temperatures.
© 0301 0299 6479-0125 JC 08 - Page 3

Lube oil system
08.02.01
JC 08 - Page 4 0299 6479-0125 © 0301

Lube oil system
08.02.02
Lube oil change
Tools
- Standard tools
Cross-references
- Job Card 08.01.01, 08.02.01
Maintenance Caution!
The time to change the lube oil will depend largely Make sure all piping is tight.
on the quality of the lube oils being used, the quality
circulating inside the engine’s lube oil system, the
engine’s lube oil consumption, and the effectiveness
of the filtration involved.
Note
For the above reasons, the manufacturer cannot
specify guideline figures for lube oil change times.
You must change the lube oil whenever, on the
basis of lube oil examinations (see Job Card
08.01.01) there is any doubt on whether the lube oil
can continue to be used.
For lube oil recommendations in dependence on
fuel and engine utilization, see “Instructions on
expendables”.
Job
With engine in hot condition, check that valves are
proverly positioned and drain oil from sump or extra
tank, using the priming pump as required.
After opening drain and bleed holes, drain oil from
filters, cooler and all piping.
Clean oil filter (Job Card 08.09.02), crankcase
interior and oil tanks, as required.
For filling in the fresh oil, close all drain and bleed
holes, fill in oil to top mark and bleed filters etc. in
the direction of flow. Check oil level while the engine
is running and top up as required.
© 0301 0299 6479-0125 JC 08 - Page 5

Lube oil system
08.02.02
JC 08 - Page 6 0299 6479-0125 © 0301

Lube oil system
08.03.01
Lube oil pump relief valve servicing
Servicing Tools
Remove valve and clean. - Standard tools
Job
Stop engine. Shut off oil feed pipe to engine where a
high-level tank is provided.
Mark adjusting cap (10) relative to cover (6). (Never
change cap setting.)
Remove screw (7), cover (6), cap (10) with threaded
bush (9), stem (4) with cup springs (8) and plate (2)
from housing (3).
Mark cap (10) relative to bush (9). (Never dismantle
stem (4).)
Reassembling the valve
Clean all components in diesel fuel. Replace gasket
(5) and 0-seal (11) if nesessary.
Install plate (2), cap (10) plus bush (9), stem (4) and
springs (8) into housing (3). Check that marks of
cap (10) and bush (9) agree.
Install cover (6) with gasket (5) and 0-seal (11) and
secure to housing (3) with screws (7). Check that
marks of cap (10) and cover (6) agree.
Have valve adjusted on a test stand only!
Fig. 1 Relief valve (83339_0)
Caution!
Be sure oil pump (1) will never run dry!
© 0301 0299 6479-0125 JC 08 - Page 7

Lube oil system
08.03.01
JC 08 - Page 8 0299 6479-0125 © 0301

Lube oil system
08.04.01
Lube oil pump servicing
Tools
- Standard tools
- Puller
Cross-references
- Job Card 08.03.01, 04.08.01
Servicing
Dismantle pump and inspect gearshafts, bearing
and valve assemblies.
Note
Even minute foreign particles will eventually destroy
gearshafts and bearing housings.
Removing the pump
Stop engine. Isolate oil line to engine (where high-
level tank provided). Disconnect suction line (6) and
delivery line (4) from pump. Disconnect bleeder line
from delivery pump. Unscrew nuts (1). Remove
pump (5) from pump chest (3), paying attention to
both dowel pins (2).
Fig. 1 Lube oil pump (83340_0)

Dismantling the pump
Remove screws (9) and take down cover (8) with
relief valve (26) and gasket (10).
Unlock nut (19) and unscrew. Remove locking plate
(18) and washer (17). Withdraw drive gear (16) by
puller. Take out key (20). Remove screws (15) and
withdraw cover (14) from body (12) and gearshaft
(21). Remove gasket (13).
© 0301 0299 6479-0125 JC 08 - Page 9

Lube oil system
08.04.01
Press out gearshafts (21) and (22) with bearing Reassembling the pump
assemblies (25) and stop washers (24) from body Install gearshafts (21) and (22), bearing assemblies
(12). If necessary, place hard timber on shaft drive (25) with stop washers (24) and bearings (23) in
journal. body (12).
Clean all components, especially joint faces. Mount cover (8) and cover (14) with new gaskets
Examine bearings (23) for scoring, gears for wear, (10) and (13). Fit screws (9) and (15) with lock-
and bearings (25) plus stop washers (24) for friction washers.
marks. Intact components can be put back to use.
Turn gearshaft (21) to check that shafts (21) and
Where pumps are two-directional, check that valve (22) move freely in body (12).
flaps are working properly. Should springs (28) and/
or valve flaps (27) be defective, push valve assem- Fit key (20), drive gear (16), washer (17) and
blies (29) toward cover (8) out of body (12) and locking plate (18). Screw nut (19) in place, carefully
replace. When refitting valve assemblies (29), fit tighten and lock.
dowel pin in groove of body (12). This will locate Caution!
valve assemblies (29) radially. Due to lubrication, bearings (23) and (31)
may not be interchanged.
JC 08 - Page 10 0299 6479-0125 © 0301

Lube oil system
08.04.01
Refitting the pump

Position pump (5) with new gasket on pump chest
(3), locating it by dowel pins (2).
Screw nuts (1) with lockwashers in place. Measure
backlash (Job Card 04.08.01). Connect suction line
(6) and delivery line (4). Connect bleeder line to
delivery pump. On suction pump, unscrew bleeder
plug (11) and fill in regular motor oil. Refit plug.
Caution!
Gear pumps must never run dry!
Check running pump for freedom from leaks.
© 0301 0299 6479-0125 JC 08 - Page 11

Lube oil system
08.04.01
JC 08 - Page 12 0299 6479-0125 © 0301

Lube oil system
08.09.02
Automatic back-flushing filter
Maintenance
- Back-flushing filter, initially after 500 running
hours,
- Then after 1,000 running hours,
- Periodically every 5,000 running hours: Check
and clean in accordance with operating instructions
of Boll & Kirch.
© 0301 0299 6479-0125 JC 08 - Page 13

Lube oil system
08.09.02
JC 08 - Page 14 0299 6479-0125 © 0301

Lube oil system
08.11.01
Lube oil pressurestat inspection
Tools
- Standard tools
- Pocket lamp
Aids
- DEUTZ DW 60 locking compound
Cross-references
- Job Card 02.00.01
Inspection
Inspect pressurestat when system pressure falls off.
Note
Make sure that,with engine hot, the oil pressure is
as stated in the acceptance test sheet (see also
Section 3). The pressurestat is not adjustable.
Job
Read oil pressure with engine running under full
load condition. If pressure is low, stop engine and
remove pressurestat (5). Observe safety precauti-
ons (Job Card 02.00.01).
Remove blanking flange (4) form oil sump (2). Fig. 1 Pressurestat (83343_0)
Release bolts (7) and drain oil from distributor line
(6).
Unscrew bolts (7) and remove pressurestat (5) from
flange (1) of distributor pipe (6). Take guide bush (8)
with spring (11) and spindle (10) out of body (9).
Clean all components in diesel fuel. Inspect joint
faces of spindle (10) and body (9) for wear.
© 0301 0299 6479-0125 JC 08 - Page 15

Lube oil system
08.11.01
Install guide bush (8) with spring (11) and spindle

(10) in body (9).
Renew gasket (12). Apply DEUTZ DW 60 to thread
of bolts (7).
Mount pressurestat (5) with bolts (7) to flange (1) of
distributor line (6), the relief hole of pressurestat (5)
facing the bottom of sump (2).
Fit blanking flange (4) with new gasket (3) to sump
(2).
Fig. 2 Pressurestat (83344_0)
JC 08 - Page 16 0299 6479-0125 © 0301

Lube oil system
08.14.01
Valve seat lubrication gauging
Gauging Tools
The delivery of the inlet valve seat lubricating pump - Standard tools
is gauged.
- 10 cm3 graduated glass
Note Job
Gauging locations are as follows: Perform all measurements between check valve (7)
In-line engine:first and last cylinders and nozzle (3).
V-type engine:first and last cylinders of both banks. Proceed as follows:

Release pipe clip (1) and union nut (2) and insert
end of pipe (4) into the measuring glass.
Fig. 1 Valve seat lubrication (25583_0)
© 0301 0299 6479-0125 JC 08 - Page 17

Lube oil system
08.14.01
Measure oil quantity V per nozzle delivered within

one hour at rated engine speed and convert to deli-
very Qp of pump (6). Delivery of oil pump at 0.012 - 0.015 cm3/KWh
Conversion formula rated power.
0.0088 - 0.011 cm3/HPh
Qp = V * a / N
Qp = Pump delivery in cm3
V = Oil quantity determined in cm3 If the measure quantity does not agree with the
required value, this must be corrected at setscrew
a = No. of nozzles per engine (5) of oil pump (6).
N = Rated engine power in kW/HP Turning the setscrew clockwise increases the quan-
Compare Qp to oil pump delivery specification. tity delivered.
Fig. 2 Oil pump (83345_0)
JC 08 - Page 18 0299 6479-0125 © 0301

Lube oil system
08.14.01
Valve seat lubrication
Checks Tools
Visual check of the valve seat lubricating system. - Standard tools
Checking the quantity delivered.
- 10 cm3 graduated glass
Job Check at the sight-feed drip oiler (5). If the valve

Visual check: seat lubricator is in operation, drops form at the
valve of the oiler and dripdown slowly. If not, find out
the cause and remedy.
Fig. 1 Sight-feed drip oiler, In-line engine (83346_0)
© 0301 0299 6479-0125 JC 08 - Page 19

Lube oil system
08.14.01
Fig. 2 Sight-feed drip oiler, V-type engine (83456_0)
JC 08 - Page 20 0299 6479-0125 © 0301

Lube oil system
08.14.01
Checking the quantity delivered: If the measured quantity does not agree with the
This is measured after the check valve on the sight- required value, this must be corrected at setscrew
feed drip oiler (5). To do this, disconnect the pipe (2) of oil pump (1). Turning the setscrew clockwise
leading from the check valve on sight-feed drip oiler increases the quantity delivered.
(5) to the nozzle, and catch the drops of oil in a The setting quantity is:
gauge glass. Measure the oil quantity delivered over min. 0.012 cm3/kWh
a period of one hour, at engine rated speed.
max. 0.015 cm3/kWh.
Fig. 3 Oil pump (83347_0)
© 0301 0299 6479-0125 JC 08 - Page 21

Lube oil system
08.14.01
JC 08 - Page 22 0299 6479-0125 © 0301

Coolant system
09.00.01
Coolant system draining
Aids
- Compressed air
Cross references
- Job Card 10.01.01, 10.06.01
- Instructions for expendables
- Instructions for conservation
For carrying out various jobs, e.g. on cylinder head, If the engine is to be shut down for a long period, it
crankcase, turbocharger, radiator, cooling-water has to be preserved in accordance with Chapter 6.5.
pump(s) and pipings, it is necessary to partly or fully Drain off the coolant as follows:
drain off the coolant.
Close off all coolant lines to and from engine.
When shutting down the engine for a long period
and there is a risk of frost, the coolant must be drai- Open drain valves (20) at cylinders A1 and B1
ned off fully, or an antifreeze agent must be added (Detail “X”)
to the coolant.
Fig. 1 Coolant system (25467_1)
© 0301 0299 6480-0125 JC 09 - Page 1

Coolant system
09.00.01
Screw out plug(s) (1) at coolant rotary pump(s).
Fig. 2 Coolant rotary pump (25528_0)

Open drain valves (2) at charge air coolers.

Drain water from air receivers,
Drain water from pressure reducer station,
Open drain plug (if provided) on all coolant-carrying
pipes in which a water-trap can exist, otherwise loo-
sen pipe and allow water to drain off.
Drain valve cages and blow out pressure gauge line
with compressed air.
Drain water at monitoring unit for double-walled
injection lines.
Finally, reinsert all plugs, close drain valves and
refasten pipings.
JC 09 - Page 2 0299 6480-0125 © 0301

Coolant system
09.01.01
General notes on coolant treatment
General notes
Great attention must also be given to proper treat-
ment of the closed-circuit engine coolant, to avoid
the risk of engine over heating, corrosion and cavi-
tation. Note in particular the following requirements:
- Freedom of coolant from gases including air
- Sufficient coolant pressure
- Perfectly clean condition of system
- Application and servicing of suitable additives
For further general notes on the coolant system see
Chapter 6, Expendables.
© 0301 0299 6480-0125 JC 09 - Page 3

Coolant system
09.01.01
JC 09 - Page 4 0299 6480-0125 © 0301

10.01.01
Compressed air system testing/servicing
Tools
- Standard tools
Aids
- Compressed air
Cross-references
- Job Card 01.11.01
Testing Note
Check entire compressed air system for correct When refitting piping, never apply white or red lead
functioning. or varnish because this will reder any subsequent
Caution! disconnections more difficult. In addition, hardened
particles may find ingress into the system and cause
To prevent seizure by rust of the system’s damage, in particular to the system’s control valves.
control valves, drain water form system For the same reason, be sure to keep trimmings
including air receivers daily. and similar foreign matter out of the piping.
In conformity with the accident prevention Make sur that all pipe unions and connections are
regulations, the compressed air tank must tightened securely, but never with internal stressing.
be drained of water after every time it is fil- If necessary, align pipes so they fit perfectly. Do this
led. in cold condition, and never fill piping with sand or
Job similar matter. Following pipe bending, clean piping
inside from scale etc. and finally blow out.
Drain water from air receivers. If an automatic drain
valve is provided, inspect this.
Check that relief valve blows off as 30 bar are
exceeded.
Check that the system’s control valves work pro-
perly.
Servicing
Clean air piping.
Job
Close shut-off valves on air receivers. Exhaust feed
piping. Unscrew connections for control piping and
blow out any rust deposits. Refit connections.
Perform starting manoeuvre.
When starting manoeuvre is complete, check pres-
sure on air receiver and temperature of starting
valve (Job Card 01.11.01).
© 0301 0299 6481-0125 JC 10 - Page 1

10.01.01
JC 10 - Page 2 0299 6481-0125 © 0301

10.02.01
Starting pilot air distributor testing/servicing
Tools
- Standard tools
- Round-nosed pliers
Aids
- Lubricant DEUTZ S2
Cross-references
- Job Card 05.00.01
Note Job
The air coming from the master valve presses the Disconnect pipe (1) and unscrew plug (2). Remove
plungers of the air distributor into the rotating (nega- washer (3). Unscrew bolts (13). Take down cover
tive starting cam), releasing air to the starting valves (11) with 0-seal (22) and gasket (12). Press down
in the cylinder head in the correct firing order. In springs (8) by screwdriver to some extent and with-
unpressurized condition (before or after a starting draw dowel pin (6) from plunger (9) by rond-nosed
manoeuvre), the valve plungers are raised from the pliers. Remove plunger (9), lockwasher (7) and
cam by spring force. spring (8) from housing (4).
For any work on the pilot air distributor, observe Clean plunger (9). Examine plunger (9) and barrel
safety precautions in Job Card 05.00.01. (5) for scoring and smoothen as required. Apply
Testing DEUTZ S2 compound to plunger and reinstall with
lockwasher and spring. Fit dowel pin. Check that
Check that all distributor plungers move freely. plunger moves freely.
Job Fit gasket (3) and screw plug (2) in place. Connect
Remove cover (11). Disconnect air pipe (1) and pipe (1). Install hood (11) with 0-seal (22) and new
remove plug (2). Turn engine until plunger (9) to be gasket (12) on housing (4). Screw in bolts (13).
tested is in mid-position above starting cam recess
(10). Press plunger (9) down by hand and release:
plunger must come back without binding.
Servicing
Remove any binding plungers (9) and clean.
© 0301 0299 6481-0125 JC 10 - Page 3

10.02.01
Replacing the starting cam

Unscrew waisted bolt (20) from stubshaft (19) and
take down cam (10) with dowel pin (21).
Install new cam (10) with dowel pin (21) on stub-
shaft (19), screw bolt (20) in place and tighten
through 236 Nm.
Refitting the distributor
Clean joint faces of flanged bearing (18) and hou-
sing (4). Position housing (4) with gasket (16) on
bearing (18), locating it by dowel pins (14). Screw in
bolts (15) and tighten evenly.

Caution!
When work is completed, start engine
several times on air and check distributor
for proper working and freedom from leaks.
Reconditioning
Remove distributor, especially before camshaft
removal or starting cam replacement.
Place hood (11) with 0-seal (22) and new gasket
Removing the distributor
(12) on housing (4) and secure by bolts (13). Con-
Disconnect pipes (1) and (17) from distributor. nect pipes (1) and (17).
Unscrew bolts (13) and remove cover (11). Unscrew
Caution!
bolts (15). Lever off housing (4) from flanged bea-
ring (18) by means of screwdriver, paying attention When the job is completed, start engine
to dowel pins (14), and carefully remove over cam several times on air and check distributor
(10). Take down gasket (16). for proper working and freedom from leaks.
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10.02.02
Starting pilot air distributor air cleaner servicing
Tools
- Standard tools
Aids
- Detergent
Cross-references
- Job Card 05.00.01
Servicing
Clean air cleaner (1) ahead of air distributor (2).
Job
Observe safety precautions in Job Card 05.00.01.
Unscrew banjo bolts (13) from piping (3). Detach air
cleaner (1) from its support.
Unscrew bolts (12) and remove cover (5) with gas-
ket (6). Remove elements (10) and 0-seals (11)
from body (7).
Inspect elements and replace if soiled. Unscrew
plug (8). Clean body (7) inside. Screw in plug (8)
with new washer (9).
Install elements (10) with new 0-seals (11) in body Fig. 1 Air cleaner (83348_0)
(7). Fit new gasket (6). Mount cover (5) with bolts
(12) on body (7). Secure cleaner (1) to its holder.
Connect piping (3) with new washers (4) and banjo
bolts (13) to cleaner (1).
© 0301 0299 6481-0125 JC 10 - Page 5

10.02.02
Fig. 2 Air cleaner (83349_0)

Caution!
Following cleaner fitment, start engine and
check that filter is free from leaks.
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10.03.02
Dust collector cleaning
Cleaning Tools
Before cleaning the dust collector in the starting air - Standard tools
line, make sure that the shut-off valve on the com-
pressed-air receiver is closed.
Aids
- Cleaning agent
Daily open drain valve (1) on dust collector and

allow condensation of water (if any) to drain off.
Then reclose drain valve.
Clean the sieve as per Maintenance Schedule.
Job
Loosen hex. nuts (3) and take out hex. bolts (2).
Take off flange (4) and gasket (5). Remove sieve
(6). Clean sieve with a cleaning agent (e. g. cold cle-
aner) and rinse afterwards with fresh water. Then
blow out with compressed air. Renew sieve if dama-
ged. Clean sealing faces of flange and check gasket
(5), renewing if necessary.
Centre sieve together with retainer (8) in flange (4)
and introduce assembly into tube (7) taking care
that the sieve also sits in the centering of tube (7).
Now tighten hex. bolts (2) and hex. nuts (3).
Close drain valve (1), if open.
Fig. 1 Dust collector (25234_1)

X Direction of flow
© 0301 0299 6481-0125 JC 10 - Page 7

10.03.02
JC 10 - Page 8 0299 6481-0125 © 0301

10.03.11
Starting air master valve servicing
Tools
- Standard tools
- Grinding compound
Aids
- Lubricant DEUTZ S2 and DEUTZ F5
Cross-references
- Job Card 05.00.01
Servicing (R/S/BVM 640, Fig. 1)

Dismantle master valve and clean.
Job
Disconnect air pipe (22). Unscrew hex. nuts (9). Un-
screw bolts (5) and (7). Rmove elbow (6) with was-
hers (4) from master valve and air pipe (8). Do not
interchange washers (4).
Unscrew hex. nuts (2) and remove cover (21) with
lever (1). Withdraw split pin (19) and unscrew castle
nut (18) by sokket wrench, retaining valve cone by
screwdriver from below. Pull out valve (13) from
body (10) in downward direction. Unless removed
along with valve (13), take out piston (17), spring
(15) and bushes (12) and (14) from body (10).
Clean all components in diesel fuel and inspect for
wear. Examine in particular running faces of body
(10), bush (12) and piston (17) for corrosion and
scoring. If necessary, replace piston rings (11) and
(16) as well as washers (4) and (20) and regrind
valve cone on its seat by fine compound.
Unscrew grease fittings (3), wash out, fill with
DEUTZ F5 compound and screw in place again.
Fig. 1 Starting air master valve, R/S/BVM 640

(83350_0)
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10.03.11
Reassembling the valve Caution!

Apply a thin film of DEUTZ S2 on all components. Following reassembly, start engine several
Fit bushes (12) and (14) to valve (13) as shown and times to check master valve for proper wor-
introduce into body (10) from below. Install spring king and freedom from leaks.
(15) and piston (17) from above, taking care not to
damage piston rings (11) and (16). Screw castle nut
(18) in place and lock by split pin (19). Fit washer
(20).
Mount cover (21) and secure by nuts (2). Lubricate
master valve through grease fittings (3). Operate
lever (1) to check that master valve opens and clo-
ses satisfactorily.
Fit both washers (4) according to their sizes. Posi-
tion elbow (6) and secure to master valve by bolts
(5) and (7) and to starting pipe (8) by nuts (9). Con-
nect control air pipe (22).
Caution!
Following reassembly, start engine several
times to check that master valve works pro-
perly and is free from leaks.
Servicing (BVM 640, Fig. 2)
Dismantle master valve and clean. Installing place
see Job Card 10.03.91
Job
Diconnect control air pipe. Remove valve from star-
ting air pipe.
Dismantling the valve Fig. 2 Starting air master valve, BVM 640 (83351_0)
Carefully unscrew bolts (1).

Caution!
Cover (3) is springloaded.
Remove cover (3). Take washer (2), adapter (6),

spring (7) and piston (10) out of housing (8).
wear. Ecamine especially joint faces between hou-
sing (8) and piston (10) and of adapter (6) for corro-
sion and scoring. Smoothen as required. Replace 0-
seals (4) and (9). Inspect multi-disc seal (5) and
replace if necessary.
Reassembling the valve
Apply a thin film of DEUTZ S2 lubricating compound
to all components. Install piston (10) with 0-seals (4)
and (9) plus multidisc seal (5), spring (7), and adap-
ter (6) in housing (8). Fit washer (2). Secure cover
(3) to housing (8) by bolts (1).
JC 10 - Page 10 0299 6481-0125 © 0301

10.03.91
Starting air master valve running-in screen servicing
Tools
- Standard tools
Aids
- Detergent
Cross-references
- Job Card 05.00.01
Servicing
Clean screen ahead of master valve. At the end of
250 hours (or later) replace screen by a ring.
Note
All new engines are delivered with a screen ahead
of the starting air master valve for the purpose of
protecting the valve from piping scale or other for-
eign matter. After 50 running hours the screen must
be cleaned or replaced. It can be finally, removed at
the end of 250 hours, provided the cleaning solution
reveals no appreciable dirt.
Cleaning the screen (2)
Detach pipe and adapter flange (4) from master
valve (3). Remove screen (2) and clean with a suita-
ble detergent. Then flush with fresh water and blow
out with air.
Clean flange joint faces, install screen (2) and con- Fig. 1 Screen (83352_0)
nect pipe.
Finally removing the screen (2)
Remove screen as above and replace by ring (1).
Fit flange (4) and air pipe.
© 0301 0299 6481-0125 JC 10 - Page 11

10.03.91
Fig. 2 Marine propulsion engine (83353_0)
Fig. 3 Stationary engine (83354_0)
JC 10 - Page 12 0299 6481-0125 © 0301

10.06.01
Pressure reducer station servicing
Servicing Tools
Drain condensate and clean filter elements. This is - Standard tools
possible while the engine is running.
Note
In hand lever position I and III, the H.P. line is con-
nected to the L.P. line through one filter and one
pressure reducer each.
The low pressure is indicated by gauge (6) direct; it
can be adjusted with screws (5).
In lever position II, both filters and pressure redu-
cers are connected in the L.P. line. In position IV, the
H.P. line is isolated, while the L.P. line is connected
to the atmosphere.
Draining Condensate
Operate rods (1).
Cleaning the filter
Caution!
Clean only filters not in service: filter (4) in
lever position I and filter (3) in position III.
With the engine shut down, both filters can be clea-
ned in positon IV.
Procedure
Unscrew plug and remove filter. After cleaning filter,
dry by air blast. Reinstall filter and fit plug with Fig. 1 Filter (83355_0)
washer.
© 0301 0299 6481-0125 JC 10 - Page 13

10.06.01
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Monitoring system
11.01.01
Temperature switch (oil, water, air) testing/reconditioning
Testing Tools
Check the switch for correct setting and proper - Standard tools
functioning.
- Ohmmeter
The switch comprises sensor (1) with pocket (2)
(test site) and a setting unit (4) (cable terminal box). - Thermometer
Aids
- Heat conducting compound DEUTZ P1
Note
Be sure lead (7) between setting unit (4) and sensor
(1) will not chafe.
Job
Clean sensor (1) externally and check that it is firmly
seated.
Adjustment
You will find the setpoint values for the actuation
points of temperature monitors in Chapter 3 “Techni-
cal Data”.
The switching point is set on dial (3) of unit (4) with
an accuracy of 2.5 % over the entire temperature
range.
Fig. 1 Temperature switch (83356_0)
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Monitoring system
11.01.01
Testing: Replacing the setting unit:

a) Sensor (1): Remove leads and push unit (4) out of terminal bar.
Remove sensor (1) from pocket (2) and dip in hot Bevor fitting a new unit, check for agreement with
water. sensor (see above).
Use an ohmmeter to meet the electrical resi- For setting a new unit, see Chapter 3.3, “Technical
stance. By means of curves on sheet (3), com- Data” or rating plate of the old unit.
pare actual and specified values, or test as
under c).
b) Setting unit (4)
Remove unit (4) from terminal box and connect
to terminals 3 and 4 of sensor (1) in water by
means of two 1.5 mm2 leads. Apply auciliary
voltage of 24 volts to terminals 1 and 2.
Connect ohmmeter to terminals 5 and 6. Adjust
dial (3) determine trip point and compare with
water temperature.
If test result is satisfactory, seal unit with lead, or
test as under c).
or
c) Sensor (1) plus setting unit (4) as a whole
(alternatively)
Use test instrument TP 100/12 supplied by Noris
Tachometerwerk GmbH & Co., Muggenhofer Str.
95, Nürnberg, Germany.
Reconditioning
(Temperature sensor and switching device cannot
be repaired).
Replacing the sensor
With engine running, remove screws (6) and take
sensor (1) out of pocket (2).
Before fitting a new sensor, check that sensor and
setting unit are a match , i.e. their model designati-
ons must have the same figures. (Example: sensor
TH 31 will agree with setting unit RH 31.)
Fill pocket (2) with heat compound (5). (Press some
20 mm out of tube.) Secure sensor (1) by screw (6).
Caution!
Air in the pocket is liable to affect the rea-
dings.
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Monitoring system
11.01.01
Switch RH 32 A Switch RH 31
(yellow rating plate with blue dot) (white rating plate)
Sensor TH 32 Sensor TH 31
(yellow dot - yellow sensor head) (white dot - black sensor head)
Range 7 - 70 °C Range 42 - 120 °C
Fig. 2 Diagram (83357_0)
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Monitoring system
11.01.01
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Monitoring system
11.01.02
Pressure switch (oil, water, air) inspection/testing/servicing
Inspection/testing Tools
Inspect and test the switch for proper functioning - Standard tools
- Testing gauge
- Setting mandrel
- Testing hose with standard test flange
- Commercial test pump
Note Job
Pressure switches are available for the following Clean housing (1) externally. Check that all bolts/
media: lube oil, fuel raw water, fresh water, injector screws and stuffing box screwing (2) are tight. Be
coolant, control (pilot) air, starting and charge air sure no lead can chafe. Close cock (3). Unscrew
pressure. cap nut (4) and connect testing hose. Connect test
Settings are indicated on the switch in bar kp/cm2. gauge to hose flange. Subject switch to a higher
Check wether setting is to fix minimum (dropping) or working pressure by a commercial test pump.
maximum (rising) limits. (Terminal 212/212 always Check that switch actuates as the pressure falls or
for rising function.). rises (depending on setting and application). The
test gauge indicates the prevailing working pres-
sure.
Compare actual switching point (e.g. for release of
an alarm) to the preset switching point (see
Section 3).
Fig. 1 Pressure switch (83358_0)
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Monitoring system
11.01.02
Servicing Functional test

For altering the setting (switching point), loosen For testing functions of the instrument mounted on
fixing screw (6) and turn adjusting screw: clockwise the pressure switch panel, remove screwplug (4)
raises pressure, counterclockwise reduces pres- and connect in place of same the hose with test
sure. As the desired setting is obtained, lock adju- connection. To this hose can be conected a test
sting screw (7) by fixing screw (6). gauge or a test pump combined with test gauge.
Adjusting screws have RH thread. Subject switch to a higher working pressure by a
comercial test pump. Check that switch actuates as
Caution! the pressure falls or rises (depending on setting and
The integral microswitches are of the sin- application). The test gauge indicates the prevailing
gle-pole quick-action type and must never working pressure.
be removed. Nor must the sensor retaining Compare actual tripping point (e.g. for release of an
screws be slackened or removed. Be sure alarm) to the preset switching point (see Section 3).
to replace defective pressure switches as a
complete unit. Servicing
Note Setting the switching point
Pressure switches are available for the following For altering the setting (switching point), remove
media: lube oil, fuel, raw water, fresh water, injector housing cover (5) and loosen fixing screw (6) loca-
coolant, control (pilot) air, starting and charge-air ted inside the housing. The trip point is set at the
pressure. Settings are indicated on the switch in bar adjusting screw (7) with the aid of a screwdriver:
(kp/cm2). Check wether settings is to fix minimum Clockwise raises pressure, counterclockwise redu-
(dropping) or maximum (rising) limits. (Terminal 212/ ces pressure. As the desired setting has been obtai-
212 always for rising funtion). Test for proper fun- ned, retighten fixing screw (6) and replace housing
tioning has to be carried out with the unit operating. cover (5).
Clean housing (1) externally. Check that all bots/

screws and stuffing box screwing (2) are tight. Be
sure no lead can chafe. Close shut-off valve (3).

Caution!
The built-in micro switches are of single-
pole quick-action type.
Fig. 3 Pressure switch (25356_0) The screws retaining the pressure switch
must never be slackened or removed.
Be sure to replace defective pressure swit-
ches as a complete unit.
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Monitoring system
11.01.03
Warning device (Flow switch) for backleakage fuel (heatable), testing
Testing Tools
Checking the proper functioning of the warning - Standard tools
device (flow switch) for shielded injection lines.
- Funnel
Caution!
Flow switch can function properly only if
backleakage line to collecting tank is laid in
steadily descending manner feed.
Note
Alarm by the flow switch in service may be caused
by a broken injection line or a leaky connection.
Job
Clean switch externally and make sure that connec-
tions are tight. With the engine in service, unscrew
union - located on backleakage pipe between fuel
injection pump and flow switch -. Put funnel in place
on pipe connection and fill in diesel fuel. An alarm is
sounded by the flow switch which stops when the
fuel drain valve is actuated and the diesel flow
released thereby. If no alarm signal is given during
this functional check, be sure to elimate defect at
once, or replace the switch.
Note Fig. 1 Flow switch (50004_1)
Connections cable may not chafe. Look out that it is Items in Fig. 1:
properly arranged.
1 fuel feed
2 fuel overflow
3 fuel discharge
4 hot water feed
5 hot water discharge
X fuel drain valve
© 0301 0299 6482-0125 JC 11 - Page 7

Monitoring system
11.01.03
JC 11 - Page 8 0299 6482-0125 © 0301

Monitoring system
11.01.04
Exhaust gas thermocouples removal/refitment
Tools
- Standard tools
Note Refitting the thermocouple

The temperature reference junction (TH 51) is loca- Introduce thermocouple (21) into cover tube (22),
ted in terminal box K VI. lock tight the union nut (20). Slip cable (17) through
Removing the thermocouple rubber sleeve (14) and slide through screw union (3)
of terminal box (19). Pull tight the screw union (3).
Stop engine. Connect cable (17) to the resp. terminals. Fit cover
Remove cover of terminal box (19). Disconnect to terminal box (19).
cable (17) at terminals and pull through released Check exhaust gas temperature reading on the run-
screw union (3). Pull out cable through rubber ning engine. If necessary, perform comparative
sleeve (14). Unscrew union nut (20) and pull ther- measurement (Job Card 11.01.05).
mocouple (21) out of cover tube (22). Cover tube
(22) of thermocouple must remain in place when Caution!
work is carried out on the running engine. Never bend cable (17) sharply.
Fig. 1 Thermocouples (25591_0) Fig. 2 Thermocouples (25592_0)
© 0301 0299 6482-0125 JC 11 - Page 9

Monitoring system
11.01.04
JC 11 - Page 10 0299 6482-0125 © 0301

Monitoring system
11.01.05
Exhaust gas thermocouples testing
Tools
- Standard tools
- mV-meter
- Thermometer
Cross-references
- Job Card 11.01.04
Testing
Perform a comparative measurement if, e.g., the
readings of thermocouples differ substantially or a
thermocouple has failed entirely.
Job
Stop engine. Remove thermocouple (Job Card
11.01.04). Perform comparative measurement with
a new thermocouple or one that has been removed
from an adjacent cylinder head. Refit a new or used
thermocouple (Job Card 11.01.04).
Comparative measurement
(see also illustration for Job Card 11.01.04)
Start engine and run up to service temperature. Dis-
connect ongoing cable in terminal box (KVI or 19)
and connect mV-meter instead.
Soldered point (1): negative lead (green) (Ni)
Soldered point (3): positive lead (red) (NiCr)
Fig. 1 Thermocouples (25594_0)
Read off mV-value.
Guage temperatur of reference junction in terminal
box and read corresponding mV-value off the table
below. Add both mV-values. Read corresponding
exhaust gas temperature from table.
Note
If the point for connecting the mV-meter had been
removed from the terminal box, gauge the tempera-
ture prevailing at the place where the point is loca-
ted at that moment.
© 0301 0299 6482-0125 JC 11 - Page 11

Monitoring system
11.01.05
Table for converting temperatures and mV-values

Material of thermocouple NiCr-Ni (DIN 43 710).
Ref. temperature 0 °C.
Fig. 2 Table (25593_0)
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Monitoring system
11.03.01
Engine safety system Noris KN 923
Testing
When the engine is about to exceed critical limits,
the safety system will stop the engine by cutting fuel
supply.
Note The operating switch connected to terminal 295

Automatic overspeed stop uses model GZ 121 B prevents the limit value generator becoming ope-
tacho-generator. rative when starting, stopping or reversing the
engine. Operating switch and firing speed con-
Automatic low-oil-pressure stop uses an oil pres- tact must agree. Failing this, the alarm “Failure of
sure switch. Safety System” is given. When the engine is sta-
Manual emergency stop uses stop botton. tionary, the operating switch is closed.
Manual emergency operation uses reset button 3. Manual emergency stop
from wheelhouse or whellhouse or control room, but Two inputs (monitored for wire failure) for energi-
not when emergency/overspeed stop is provided. zed tripping are provided. The casing contain
Description of working principle another emergency stop button. To prevent acci-
dental operation, this button is locked by a cover.
1. Overspeed stop
If necessary, two more buttons can be connected
This stop is released by the tachogenerator. The to the two inputs mentioned, but these buttons
stop command will be stored, i.e. it will be main- are not safe against wire failure. Therefore,
tained even as the fault condition goes down these buttons must not be wired for resistors.
beyond the critical limit. For restarting the Pressing one of these bottons will stop the
engine, reset button b1 (Figure 1) must be pres- engine. The emergency stop signal is stored and
sed (not possible with reset button in wheel- maintained until cancelled by pressing reset but-
house or control room). ton b1 (Fig. 1).
For incorporated test outfit see test program
“Overspeed”.
2. Automatic stop with limit value generator
(Energized tripping)
The limit value generator (low oil pressure, for
instance) will respond 1 or 2 seconds after the
critical limit has been reached; the engine will be
stopped. The stop signal is stored, which means
it is maintained until the emergency operation
reset button has pressed.
Under emergency conditions, the stop signal can
be cut out by pressing the emergency operation
button.
© 0301 0299 6482-0125 JC 11 - Page 13

Monitoring system
11.03.01
4. Testing outfit 6. Setting the speed tripping points

This outfit makes sure that the system is working The tripping points are set with the drum scale
properly. (Fig. 2).
4.1The limit value generator, e.g. for oil pressure, Once the module is inserted, the drum scale can
and the two outputs for stopping solenoids 20A/ be adjusted with the index finger.
3A are part of a deenergized tripping circuit to (a) Firing speed:
indicate any interruption. This funtion can be
tested. The safety circuits are interrupted by With engine running at lowermost speed, the
pressing the buttons on the from panel of the drum scale is slowly adjusted from 10 towards 0
associated plug-in modules. By interupting one (zero point), until the pilot light goes on. Then
or more cicuits, the alarm contact “safety system check that light goes out as the engine is stop-
failure” must open and the externally connected ped.
deenergized alarm system must indicate the (b) Overspeed:
fault. At the same time the green light diode With engine running at working speed, press test
associated to the circuit must go out, while the button and adjust drum scale slowly from 10
collective alarm light for “wire falure” is on. towards 0, until pilot light goes on. Release but-
4.2Overspeed test with engine running. ton and check that light goes out. The tripping
The test button on the overspeed limit switch will point is thus preset at 115 %:
lower the tripping point to 85 % of maximum per-
7. Fault-finding test program,
missible speed.
see JC 11 - Page 18 to 25
Example:
Rated speed = 650/min. Admissible overspeed = 7.1External wiring
1.15 x 650 = 747.5/min, so 85 % of overspeed is The limit value generators use energized tripping
0.85 x 747.5 = 635/min. The current to the sole- and are monitored for interruption by a small
noids is interrupted and the selfholding (storage) deenergized tripping circuit. The limit generators
function eliminated. As the engine is slowly run should be connected to the contact with a
up while pressing the test button, the overspeed 22 kOhms 0.3 watts resistor. If no resistor is pro-
limit switch must trip at 85 % of overspeed. vided or a limit generator not connected, alarm
Alarm light “overspeed” must be on. for “wire failure” is given. The outputs of termi-
5. Functioning monitoring nals 87/88 and 290/4 are monitored for wire
failure. If no solenoid is connected to the outputs
5.1Auxiliary voltage and fuses:
or output relay d3/d4 missing, wire failure alarm
As the auxiliary voltage or the fuses on the alarm is given. Outputs not required should be connec-
module fails, the associated white light connected to a 22 kOhms resistor. Inputs for emergency
ted to the mains system will go out. The external operation and operating switch are not safeguar-
alarm system indicates “Safety system failure”. ded against wire failure.
5.2Monitoring wire failure. 7.2Auxiliary voltage
The input/output units monitored for wire failure The limit must be stricly observed and to be
will be included in a small deenergized tripping tested with a special outfit. Where the auxiliary
circuit to indicate any interruption. voltage is not a clean d.c. voltage, but an uns-
When such interruption occurs, the associated creened rectified a.c. voltage, the proportion of
red light for “wire failure” will go on. The internally upper harmonics should be measured. Fitted on
associated green light diode will go out and the the SA 295/2 alarm module are the auxiliary
alarm “safety system failure” given. voltage fuses for the electronics. For replacing
5.3Tachogenerator with drive: fuses, pull out module after releasing the lock.
The monitoring system is to show agreement 7.3Speed switches
between the external operating switch, required The speed switches can be tested in operation
for stop suppresson of the limit value generators (see 6.).
with oil pump fitted, and the internal firing speed
Should switches not trip although auxiliary
contact. If there is no agreement, the alarm
voltage is correct, check connection between
“safety system failure” is given.
tachogenerator and KN 923 system: the correct
With this Noris KN 923 safety system, tachoge- terminals must be interconnected.
nerator and operating switch failure is indicated
by the means light being on and wire failure light
being off.
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Monitoring system
11.03.01
7.4Emergency stop 8. Specification data

The emergency stop is safeguarded against wire
failure. Buttons should be connected to a
22 kOhms resistor. If there is no such resistor, or Auxiliary voltage 24 volts 20%
if a button is not connected, wire failure alarm is
given (see 3.). Max. upper harmonics 5%
7.5Engine stopping through limit value generator Voltage drop 40% 5ms
Read setting instruction for the unit used (see
related Job Card). The wiring is monitored for Voltage peaks, max. 20ms, max. 60 volts
failure. To check functioning of the wire failure Power input 1 A emergency stop,
alarm, press test buttons on SA298/5 universal 2 A safety system
relay module.
7.6Resetting and emergency operating
Resetting is possible only with operating switch
in “stop” position and the fault being eliminated.
Emergency operation is not possible when over-
speed prevails. Since the wiring is not safeguar-
ded against wire failure, it must be tested.
7.7Stopping solenoids
Outputs for 20 A at terminals 87/88 and for 3 A at
terminals 290/4 are monitored for wire failure.
Outputs for 1 A at terminals 288/4 and 291/4 are
not so safeguarded.
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Monitoring system
11.03.01
Safety system KN 923
25301_0
b3 Emergency stop
b2 Light test
b1 Reset
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Monitoring system
11.03.01
Overspeed limit switch SA 297/1 G IV
83361_1
1 Drumscale
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Monitoring system
11.03.01
Test program “Auxiliary voltage”
Test Program
"Auxiliary voltage"
Aux. voltage no Remove

24 volts +/- 20% external faults
available
yes
Replace fuses
no
Short yes Remove

circuit short circuit
existing
yes
Mains Fuse Replace

no no
light on defective mains light
yes
Auxiliary voltage working
83360_0_en
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Monitoring system
11.03.01
How to eliminate a short circuit

1. Disconnect all input and output units.
2. Remove all modules from cassette.
3. Replace fuse on SA 295/2 and reinstall latter in
cassette.
4. Check that input and output units have no short-
circuits.
5. Connect input and output units and plug modules
into cassette. Observe mains light.
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Monitoring system
11.03.01
Test program “Firing speed”
Engine stationary Engine running
yes Firing speed light Firing speed light yes

off on
no no
Firing speed low Firing speed high
no
Pilot light
defective
Relay d8 and d9 Relay d8 and d9

energized deenergized
no yes yes no
Relay defective Firing speed Module A 08/09

switch operating defective
83362_0_en
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Monitoring system
11.03.01
Test program “Overspeed”
Engine running at 100%

rated speed
Test button on module "A"

04/05 pressed
Light "overspeed" on Alarm "overspeed" released

yes yes
no no
Pilot light Overspeed switch point Alarm system

defective defective
no no no
Replace module A 04/05
KN 923 system
working
83363_0_en
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Monitoring system
11.03.01
Test program “Emergency stop”
Engine stationary or running
Reset button on KN 923 1x pressed once
Emergency stop button 1x pressed once no Remplacer témoin

Emergency stop light on
Stopping solenoids Alarm "emergency stop" given

energized
yes no no yes
Test wiring
see program on page 19
Replace module A 02
Press reset button on KN 923
Stopping solenoids Alarm "emergency stop" off

yes energized no
no yes
Emergency stop working
83364_0_en
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Monitoring system
11.03.01
Test program “Limit value generator”
Contact on contact lever opened
yes
Limit value Limit value

contact 1 closed contact 2 closed
yes yes
Alarm system trips
Stopping solenoids see test program on page 19

energized
no
Press emergency operation Replace module A 06

button
Stopping solenoids Check wiring of emergency

deenergizes operation button
no
yes
KN System working
83365_0_en
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Monitoring system
11.03.01
Test program “Wire failure”
Wire failure light on
Alarm released for "Failure of

alarm system"
Green light diode Green light diode

dark on module A 03 dark on module A 06
Diode Diode indicates

trouble on Limit value generator
indicates connected
trouble on stopping
solenoid
relays d3, d4
If necessary, Stopping Resistor 22k parallel to

replace relay solenoid generator contacts correct
connected
Inspect wiring and Check wiring to limit value

solenoid for generators for interruption
interruption
Replace module A 02 Replace module A 06
83366_0_en
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Monitoring system
11.03.01
Test program “Tachogenerator”
Alarm "Safety system failure" released
Light for wire failure not on
Engine stationary Engine running
Control lever contact terminal Firing speed light on

295/295 closed
no yes yes no
Control lever Check wiring Press test Firing speed

in STOP button on contact sect
position module A 03 correctly
Control air for Tachogenera

Check relay Wire failure
pressure tor
d6 light defective
available connected
properly
Check wiring
Test program
to control
"Wire failure"
lever contact
Measure tachogenerator
voltage and inspect
tachogenerator drive
83367_0_en
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Monitoring system
11.03.01
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Monitoring system
11.03.01
Engine safety system Noris KN 910
Testing
When the engine is about to exceed critical limits,
the safety system will stop the engine by cutting fuel
supply.
All testing work should be carried out in accordance
with the manufacturer’s operating manual.
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11.03.01
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11.03.01
Overspeed protection
Check procedure
Check electrical overspeed protection device Type
Noris No.: KN 20, KN 21, KN 22 for proper
functioning, and re-adjust if necessary. Depending
on the particular device model involved, you set eit-
her 50 % or 85% of an engine overspeed. See the
rating plate for details.
Note 2. Checking a preset overspeed protection

The pick-up of the speed measuring system con- device
trols a two-position controller, whose output relay is - Operate your engine at a relatively low idling
used to operate the engine’s shutdown unit, either speed.
directly or through a contactor. Once the switching - Press the button for function-testing the over-
device’s hysteresis falls below the prescribed level, speed protection feature.
the engine will continue to be halted, thanks to an
electrical lock-in feature. - Increase the engine’s speed.
Job - At 50 % or 85 % of the engine’s overspeed, the
red lamp of the overspeed alarm must light up.
1. Setting the overspeed protection device
- Release the function test button.
- Run our engine at test speed.
3. Checking an adjusted overspeed protection
● How to determine the test speed for devices set device until engine standstill
to 50 % of the overspeed.
- Set knob at overspeed protection device to maxi-
Example: rated speed = 600 1/min mum value.
Overspeed = 1.1 x 600 = 660 1/min - Run your engine at rated speed.
50 % of overspeed = 0.5 x 660 = 330 1/min = test - Turn the knob anti-clockwise until the engine
speed shuts down.
● How to determine the test speed for devices set You will then have to re-adjust the device – see
to 85 % of the overspeed. Section 1 above.
Example: rated speed = 600 1/min Setting value
Overspeed = 1.1 x 600 = 660 1/min The overspeed you should normally set lies 15 %
85 % of the overspeed = 0.85 x 660 above the rated speed. For exceptional cases,
= 561 1/min = test speed please get in touch with DEUTZ company head-
- Set knob of overseed protection device to maxi- quarters beforehand.
mum value. (scale is not in calibrated in rpm).
- press button for function test, and turn knob anti-
clockwise until the red ”overspeed” lamp just
lights up.
- Release the function test button, and secure
knob in this position against rotation.
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11.03.01
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Monitoring system
11.05.01
Crankcase oil mist detector checking/servicing
Checking and servicing

- Cleaning the optical components, initially after
25 h
- Cleaning the optical components, periodically
every 250 h
- Checking and servicing, periodically every
1000 h
All checking and servicing work should be carrid out
in accordance with the manufactorer’s operating
manual.
Fig. 1 Crankcase oil mist detector (25577_0)
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11.05.01
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Monitoring system
11.06.01
Charge air water detector testing
Testing Tools
Test water detector for proper funtioning. - Standard tools
Note
The detector is located beneath the charge air pipe.
When water collects in the charge air pipe, due for
instance to a charge cooler leak or the temperature
not reaching the dew point, the water level will rise
in container (4) and release an alarm. In this case
be sure to remedy the trouble immediately.
Job
Unscrew plug (3) and fill container (4) with water up
to overflow port (2), whereupon sensor (1) should
cause an alarm. Failing this, inspect sensor and, if
necessary, replace.
Following this test, refit plug (3) with a new joint
washer. Drain water through cock (5).
Fig. 1 Charge air water detector (83368_0)
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Monitoring system
11.06.01
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Monitoring system
11.07.01
Float switch checking
Tools
- Standard tools
- blunt wooden rod ø8 mm, about
100 mm long
Cross-references
- Job Card 02.00.01
The float switch is installed in the oil pan at the cou-

pling end.
Checking
Check switch point of float switch while engine is
stopped.
An oil-level monitor may be present in the lube oil
pan, depending on the monitoring system specifica-
tion.
In the case of engine plants with high-level oil tank,
the switch point of the float switch is set for rising oil
level (max. warning).
In-line engines:
On the camshaft side, remove side cover of timing
chest.
V-type engines:
On the A-side, remove side cover of timing chest.
Insert wooden rod (e.g. blunt end of pencil) through
one of the holes in the bottom of the float switch and
lift the float until the warning system responds.
If no alarm is given, this means that there is a fault
in the system which must be remedied as soon as
possible. Fit new float switch if necessary.
Caution!
On no account may a sharp instrument, Fig. 1 Float switch (50100_0)
such as a screwdriver, be used to lift the
float. Do not use force to move the float.
Make sure that nothing falls into the oil pan.
The cable connected to the float may not
chafe.
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Monitoring system
11.07.01
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Monitoring system
11.08.01
Main bearing overtemperature alarm
Tools
- Standard tools
Aids
- Locking compound DEUTZ DW 60
- Heat conducting compound DEUTZ P1
Removing the sensor from hex. bolts (1) and (2). Release screw (1),
Release central bolt with knurled head (9) on socket remove pipe clip and take down sensor (6) plus
(3). Withdraw socket upwards. Remove locking wire complete retainer.
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Monitoring system
11.08.01
Replacing the sensor Refitting the sensor

Remove gasket from plug (4). Release slotted To begin with, clean hole. Install sensor (6) with
screws (8) and reaise plug (4). Separate wire ends complete retaining plate. Insert sensor (6) with heat
from soldering point, remove clamping screw (7) conducting compound P1 (10). After alignment, tigh-
and pull out sensor (6) from retaining plate. Intro- ten clamping screw (7) firmly. Lock bolts (1) and (2)
duce new sensor (6) and attach to plug (4) by solde- by wire, keeping plug (4) and socket (3) perfectly
ring with thin. Position sensor so that the support clean. Install socket (3) and tighten central bolt (9)
tube end will be flush with recess bottom edge and through 0.5 - 0.6 Nm.
tighten clamping screw (7) slightly. Tighten plug (4)
fully, seeing to it that gasket will be properly seated.
Fit slotted screws (8) with locking compoung
DEUTZ DW 60.
Fig. 2 Sensor (50051_0)
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12.01.01
Viscous-type vibration damper removal/refitment, In-line engine
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 04.08.01, 04.14.01
Note
The maximum service period of the damper is
30,000 running hours. Reconditioning can be made
by the manufacturer only.
Job
Remove pump chest (Job Card 04.14.01).
Attach gear (3) to hoist.
Unscrew waisted bolts (5). Take down bushes (4),
gear (3) and adapter (7).
Retain damper (2) by hoist.
Remove screws (6) and carefully withdraw damper
from crankshaft (1).
Clean all parts and joint faces between crankshaft
and new damper.
Install new damper (2) on crankshaft (1). Turn in
screws (6).
Mount adapter (7), gear (3) and bushes (4) by wai-
sted bolts (5) and tighten as per tightening instruc-
tions.
Refit pump chest (Job Card 04.14.01).
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12.01.01
Fig. 1 Vibration damper (83369_0) Fig. 2 Vibration damper (83370_0

Fig 1: 6-cyl.-Marine propulsion engine and Fig. 2: 8-cyl.-Marine propulsion engine
8-cyl.-Stationary engine
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Other components
12.01.01
Viscous-type vibration damper removal/refitment, 16-cyl.
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 04.08.01, 04.14.01
Note
The maximum service period of the damper is
24,000 running hours. Reconditioning can be made
by the manufacturer only.
Job
Attach gear (1) to hoist.
Remove with bushes (4) and adapter (5) by un-
screwing hex. waisted bolts (3).
Retain damper (8) by hoist.
Unscrew hex. waisted bolts (2) and straightly with-
draw damper from crankshaft.
Clean joint faces between crankshaft and new dam-
per.
Install new damper (8) on crankshaft (6). Observe
installation position.
Screw in hex. waisted bolts (2) with washers (7) and
tighten as per tightening instructions.
Mount adapter (5), gear (1) and bushes (4) after cle-
aning joint faces by using hex. waisted bolts (3) and
tighten these as per tightening instructions.
Refit pump chest (Job Card 04.14.01).
Fig. 1 Vibration damper (83457_0

X: Observe during installation
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12.01.01
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12.01.01
Geislinger torsional vibration damper (D 72/11) removal/refitment,

12-cyl.
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 04.08.01, 04.14.01, 12.01.02
Note Caution!
The maximum service period of the Geislinger tor- With properly functioning oil supply and
sional vibration damper is 24,000 running hours. connected standby lube oil pump, oil must
Removing the damper leak out of the 1 mm bores of the two screw
plugs (9).
The location of the two screw plugs (9) is marked
Attach gear (3) to hoist. with “X” on the front side of the damper.
Screw out hex. waisted bolts (5). Withdraw bushes
(4) and gear (3).
Retain torsional vibration damper (2) by hoist.
Remove screws (6) and withdraw damper (2) toge-
ther with adapter (7) from crankshaft (1).
For servicing/reconditioning,
Refitting the damper
and torsional vibration damper.
Install damper (2) with adapter (7) on crankshaft (1)
and screw in bolts (6).
Mount gear (3) and bushes (4) by using hex. wai-
sted bolts (5) and tighten them as per Tightening
instructions.
Refit pump chest (Job Card 04.14.01) and check
gear backlash (Job Card 04.08.01).
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12.01.01
Fig. 1 Torsional vibration damper (25461_1)
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12.01.01
Geislinger torsional vibration damper (D 90/26) removal/refitment,

12-cyl.
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 04.08.01, 04.14.01, 12.01.02
Note Caution!
The maximum service period of the Geislinger tor- With properly functioning oil supply and
sional vibration damper is 24,000 running hours. connected standby lube oil pump, oil must
Removing the damper leak out of the 1 mm bores of the two screw
plugs (9).
The location of the two screw plugs (9) is marked
Attach gear (1) to hoist and remove with bushes (4) with “X” on the front side of the damper.
and adapter (5) by unscrewing hex. waisted bolts
(3).
Retain damper by hoist.
Unscrew bolts (2) and straightly withdraw damper
from crankshaft (6).
For servicing/reconditioning,
Refitting the damper
and torsional vibration damper.
Install damper (8) on crankshaft (6).
Screw in hex. waisted bolts (2) with washers (7) and
tighten as per Tightening instructions.
Mount adapter (5), gear (1) and bushes (4) after cle-
aning joint faces by using hex. waisted bolts (3) and
tighten these as per Tightening instructions.
Refit pump chest (Job Card 04.14.01) and check
gear backlash (Job Card 04.08.01). Fig. 1 Torsional vibration damper (25462_1)
© 0301 0299 6681-0125 JC 12 - Page 7

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12.01.01
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12.01.02
Geislinger torsional vibration damper, servicing/reconditioning, 12-cyl.
Tools
- Standard tools
Cross-references
- Job Card 12.01.01
- Instruction Manual of Messrs. Geislin-
ger
Job
For removal of torsional vibration damper,
Unscrew hex. bolts (3) and remove the two side pla-
tes (1) and (10).
Replace O-seals (11) and (13) by new ones.
Remove damper, replace O-seals and refit damper
as specified in Instruction Manual for Geislinger
vibration dampers.
Before refitting damper check leaf springs installed
in damper, i.e. measure total clearance between
inner spring ends and inner grooves (See also
Instruction Manual of Messrs. Geislinger).
If the total clearance equals or exceeds the maxi-
mum permissable value, reconditioning will have to
be made by a Service Shop of Messrs. Geislinger.
For dampers D 72/11 tighten hex. bolts (3) to
140 Nm and for dampers D 90/26 to 225 Nm.
Fig. 1 Vibration damper(25463_0)
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12.01.02
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Other components
12.04.01
Vulkan coupling, removal/refitment (Series 1300, 1301, 1500 and 1501)
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 12.04.02
Note
Where a flywheel brake drum is provided, proceed
by removing first this drum (Job Card 12.04.02).
Removing the coupling
Retain coupling (9) by hoist. Mark coupling (9) to fly-
wheel (6). Unscrew hex. bolts (3), remove locking
plates (4) and sleeves (5). Withdraw coupling (9)
from output shaft (1).
Refitting the coupling
Clean joint faces of flywheel (6) and coupling (9).
Fit key (2) in groove of output shaft (1) and install
coupling (9). Position coupling (9) on flywheel (6).
Drive the two dowel pins (8) in the bores provided.
Screw in hex. Bolts (3) fitted with locking plates (4)
and lockwashers (10), and tighten crosswise to spe-
cification.
Fig. 1 Vulkan coupling (83371_0)
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12.04.01
Tightening Specification for hex. bolts (3)
Vulkan coupling Preloading Nm Tightening

1st stage 2nd stage
EZ 195 S 69 45° 30°
EZ 201 S 128 60° 30°

EZ 230 S
EZ 235 S
EZ 241 S
EZ 275 S
Caution!
Check that coupling (9) runs without running
or side deflections according to the manu-
facturers’s instructions.
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12.04.01
Vulkan coupling, removal/refitment (Series 1100 and 1101)
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 12.04.02
Note
Where a flywheel brake drum is provided, proceed
by removing first this drum (Job Card 12.04.02).
Removing the coupling
Retain coupling (7) and adapter ring (5) by hoist.
Mark coupling (7) to flywheel (6). Unscrew hex.
bolts (3) and withdraw dowel pins (8).
Remove adapter ring (5) after pushing output shaft
(1) aside or taking it down. Withdraw coupling (7)
from output shaft (1).
Refitting the coupling
Clean joint faces between flywheel (6), adapter ring
(5) and coupling (7).
Fit key (2) in groove of output shaft (1) and install
coupling (7). Position coupling (7) and adapter ring
(5) on flywheel (6). Drive the two dowel pins (8) in
the bores provided. Screw in hex. bolts (3) fitted with
locking plates (4) and lockwashers (9), and tighten
corsswise to specification.
Fig. 1 Vulkan coupling (83372_0)
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12.04.01
Tightening Specification for hex. bolts (3)
Vulkan coupling Preloading Nm Tightening

1st stage 2nd stage
EZ 195 S 69 45° 30°
EZ 201 S 128 60° 30°

EZ 230 S
EZ 235 S
EZ 241 S
EZ 275 S
Caution!
Check that coupling (7) runs without running
or side deflections according to the manu-
facturers’s instructions.
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12.04.02
Flywheel brake drum removal/refitment
Tools
- Standard tools
- Hoist
Cross-references
- Job Card 12.05.01
Note
Direct-reversing engines and engines using an
overhung flywheel are provided with a flywheel
brake drum between drive coupling and output shaft
for faster slow-down of engine speed.
Removing the drum
Detach brackes from their bracket (Job Card
12.05.01). Retain drum (2) by host. Mark output
shaft (5) to drum (2) and drum to coupling flange (6).
Pull out split pins (4), unscrew castle nuts (3) and
remove fitted bolts (1). Move output shaft (5) aside
or take down. Remove brake drum.
Refitting the drum
Clean joint faces of coupling (7), drum (2) and shaft
(5).
Position drum (2) on flange (6) and shaft (5) on
drum (2), paying attention to marks. Fit bolts (1).
Screw castle nuts (3) in place, tighten crosswise
and secure by split pins (4).
Mount brakes on brackets (Job Card 12.05.01). Fig. 1 Brake drum (83373_0)
Caution!
Check that coupling (7) runs without run-
ning or side deflection according to the
manufacturer’s instruction.
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12.04.02
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12.05.01
Flywheel drum brake servicing (Single-piston type)
Servicing Tools
Dismantle brake and clean, especially if the brake - Standard tools
has seized or oil leaks out of check holes “X”.
Aids
- DEUTZ F5 lubricating compound
Removing and dismantling the brake

Drain oil. Withdraw oil pipe (4) after releasing
square flange (3) from cover (5). Detach complete
brake form bracket.
Pull out split pin (15). Unscrew castle nut (14). Take
down washer (16). Pull off brake shoe (12).
Unscrew nuts (6). Remove cover (5) and gasket (1).
Remove spigot screw (21). Push piston (9) out of
cylinder (7). Remove springs (11).
Cleaning the brake
Clean all metallic parts i diesel fuel and inspect for
wear.
Unscrew both lube fittings (18) and clean oil dril-
lings. Make sure that brake linings (13) are not
worn. Renew gasket (1).
For replacing V-seal (10), unscrew hex. bolts (19)
following removal of locking wire. Take down pres-
sure plate (20) and take V-seal (10) out of piston (9).
Check that passages (8) are free.
Install new V-seal (10). Secure thrust plate (20) by
bolts (19) and lock bolts.
Fig. 1 Flywheel drum brake(83374_0)
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12.05.01
Reassembling and refitting the brake

Install springs (11) and piston (9) in brake cylinder
(7). Fit screw (21) with washer so its parallel end
engages in the groove of piston (9). Mount cover (5)
with new gasket (1) and screw nuts (6) in place after
fitting lockwashers. Attach shoe (12), paying atten-
tion to dowel pin (17). Fit washer (16), screw castle
nut (14) in place and secure by split pin (15). Screw
in lube fitting (18). Apply DEUTZ F5 lubricating com-
pound to piston (9) and shoe (12).
Following attachment of brake to bracket, connect
oil line (4) with square flange (3) and new gasket to
cover (5). Fill in oil Release plug (2) to bleed brake
until oil emerges. Tighten plug (2). Release spigot
screw (21) for final bleeding. Apply brake and check
for proper functioning and tightness.
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12.05.01
Flywheel drum brake servicing (Twin-piston type)
Servicing Tools
Dismantle brake and clean, especially if the brake - Standard tools
has seized or oil leaks out of check holes “X”.
Aids
- DEUTZ F5 lubricating compound
Removing and dismantling the brake Check that passages “A” in piston (5) , “B” in piston
Drain oil. Withdraw oil pipe (4) after releasing (14) and “C” in cylinder (12) are free. Install new V-
square flange (3) from cover (6). Detach complete seals (8) and (15)/(22).
brake from bracket. Secure thrust washers (7) by bolts (10). Lock bolts
Pull out split pin (20). Unscrew castle nut (19). Take in pairs by wire. Renew gaskets (9) and (27).
down washer (21) and pull off brake shoe (17).
Unscrew hex. nuts (1). Take down cover (6) with
gasket (9). Take piston (5) and springs (29) out of
brake cylinder (12).
Unscrew hex. nuts (28). Remove brake cylinder (12)
with gasket (27). Remove spigoted screw (26). Take
piston (14) and springs (16) out of brake cylinder
(13).
Cleaning the brake
wear. Unscrew both lube fittings (25) and clean lub-
ricating holes. Examine brake facings (18) for wear
and replace if necessary.
Remove locking wires for replacing V-seals (8) and
(15)/(22). Unscrew bolts (10), take down thrust pla-
tes (7) and remove V-seals from piston (5) and (14)
and cylinder (12) respectively.
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12.05.01
Fig. 1 Flywheel drum brake (25464_0)

Reassembling and refitting the brake After mounting brake to bracket, secure oil line (4)
Install springs (16) and piston (14) in cylinder (13). to cover (6) by square flange (3) and new gasket.
Fill in oil. Release plugs (2) and (26) to bleed brake
Fit screw (26) with washer so that its parallel end until oil comes out. Tighten plugs.
engages in the groove of piston (14). Mount cylinder
(12) with gasket (27) to cylinder (13). Screw in hex. Apply brake and check that it works properly and
nuts (28) with lockwashers. Install springs (29). has no leaks.
Install piston (5) so that bolt (23) engages in the
mating piston hole. Fit cover (6) with gasket (9).
Screw hex. nuts (1) with lockwashers in place.
Install shoe (17), locating it by dowel pin (24). Fit
washer (21), screw castle nut (19) in place and
secure by split pin (20). Screw lube fitting (25) in
place.
Apply DEUTZ F5 lube compound to piston (14) and
shoe (17).
JC 12 - Page 20 0299 6681-0125 © 0301

R/S/BVM 640 Sundry other
instructions
9 Sundry other instructions
© 0801 0299 4176-0125 Chapter 9 - Page 1

Sundry other R/S/BVM 640
instructions
Chapter 9 - Page 2 0299 4176-0125 © 0801

Service
Knowing it’s DEUTZ
DEUTZ has always stood for excellence in motor construction, pioneering many developments in the industry.
As an independent motor manufacturer, we offer — worldwide — a comprehensive range of diesel and gas
motors spanning from 4kW to 7,400kW. Our products are perfectly tailored to meet our customers’ individual
requirements.
Over 1.4 million DEUTZ motors do their job reliably all over the world. We are determined to preserve the high
standard of performance and dependability of our motors, thus keeping our customers satisfied at all times.
Therefore we are represented worldwide through a network of highly competent service partners who will meet
the needs of our customers, wherever they are.
This is why DEUTZ is not only the name for motors which pack a lot of inventive genius. DEUTZ also means
reliable service and comprehensive support to enhance your motor’s performance.
This index Sales & Service offers you an overview of the DEUTZ partners in your vicinity, including the products
for which they are responsible and the range of services provided. But even when no direct product
responsibility is mentioned, your DEUTZ partner will be happy to help you with expert advice.
The Index is constantly updated. Please ask your DEUTZ service partner for the latest edition.
DEUTZ AG — at your service.
Obtainable from the local service Partner reponsible for you or from: DEUTZ AG
Deutz-Mülheimer Str. 147-149
D-51063 Köln
Phone: 0049-221-822-0
Telefax: 0049-221-822-5304
Telex: 8812-0 khd d
Service http://www.deutz.de
© 1102 0297 7474-0199 Service

Operation Manual BVM 640

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0297 …

We reserve the right to make technical alterations to the drawings

This documentation is intended for the following engine.

Ordering No. 0299 8179 en

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© 0801 0299 4108-0125 Page III

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Care and maintenance

Careful when the engine is running!

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Page VI 0299 4108-0125 © 0801

Impressum, Forword, Contents

1 Guide to this manual

2 Layout and description of engine

2.1 Cylinder head

© 0100 0299 6462-0125 Page I

3.1 Model designation

4 Operating the engine

4.1 Preparations for commissioning the engine

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5 Engine media systems

5.1 Fuel system

© 0100 0299 6462-0125 Page III

7 Operational malfunctions, and how to correct

7.1 Table of operational malfunctions

8 Maintenance schedules and Job Cards

8.1 Maintenance schedules

9 Sundry other instructions

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1 Guide to this manual

© 0201 0299 6463-0125 Chapter 1 - Page 1

1.6 Job Card No.

Typical Job Card No.: 01.02.03, where:

01 = Maintenance Group = Cylinder head

02 = Subassembly = rocker arm bearings

1.7 Standard tools

Set of box wrenches Small water tube pliers

Srewdriver Combination pliers

Nippers Tape rule

Scriber Iron saw

Various Files Mandrel

Centre punch Hex. wrench

Socket-head wrench Non-fraying rags

Three-square scraper Grease gun

1.8 Special tools

Chapter 1 - Page 2 0299 6463-0125 © 0201

Assembly Group Job Card Maintenance Group

87 Air intake cleaner 06.03.11 06 Exhaust gas system / Charging

15 Automatic Back-Flushing Filter 08.09.02 08 Lube oil system

17 Bleeding the fuel system 07.03.02 07 Fuel system

15 Centrifugal oil cleaner 08.13.01 08 Lube oil system

38 Coolant 09.01.01 09 Coolant system

37 Coolant 09.00.01 09 Coolant system

63 Coupling/clutch 12.04.01 12 Other components

09 Crankcase vent 03.09.01 03 Crankcase

05 Crankweb deflection 02.02.01 02 Drive mechanism

32 Dust collector 10.03.02 10 Compressed air system

© 0201 0299 6463-0125 Chapter 1 - Page 3

Assembly Group Job Card Maintenance Group